WO2018105536A1 - Laminate and manufacturing method thereof - Google Patents
Laminate and manufacturing method thereof Download PDFInfo
- Publication number
- WO2018105536A1 WO2018105536A1 PCT/JP2017/043371 JP2017043371W WO2018105536A1 WO 2018105536 A1 WO2018105536 A1 WO 2018105536A1 JP 2017043371 W JP2017043371 W JP 2017043371W WO 2018105536 A1 WO2018105536 A1 WO 2018105536A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- thermoplastic resin
- resin layer
- backing member
- layer
- laminate
- Prior art date
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Images
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Definitions
- the present invention relates to a laminate having a thermoplastic resin layer, a backing member made of a tape and a polyurethane foam layer, and a method for producing the laminate.
- a laminate formed by lining a polyurethane layer foam on a skin made of a thermoplastic resin layer is widely used as an automobile interior material used for automobile interior parts such as an automobile instrument panel and a door trim. And in order to improve the designability and commerciality, the stitch pattern by sewing may be given to the skin of such a laminated body.
- Patent Document 1 when sewing a thermoplastic resin material, a sewing portion previously set at a predetermined interval on the thermoplastic resin material is melted with a heating device, Sewing along the sewing point. And in patent document 1, a sewing thread and a thermoplastic resin material are integrated by spraying a refrigerant
- a sealing tape is affixed along a seam from a back side, an adhesive is applied and dried, and a bridge
- the foaming agent and the like are prevented from leaking from the seam of the yarn by a method such as heating and melting the resin-based yarn to close the joint.
- the raw material of a foaming polyurethane layer, etc. are prevented from entering from the hole of a sewing part by laminating
- Patent Documents 1 and 2 the conventional methods described in Patent Documents 1 and 2 in which the heat treatment and the cross-linking curing treatment are performed are inferior in workability. Also, as a result of repeated studies by the present inventors, in the conventional methods described in Patent Documents 2 to 3 in which tape is applied from the back of the sewn skin, foaming is performed on the surface of the sewn thermoplastic resin layer. The components of the polyurethane layer may leak out, leaving room for further improvement.
- an object of the present invention is to provide a laminate in which the component of the foamed polyurethane layer is suppressed from leaking onto the surface of the thermoplastic resin layer even when the thermoplastic resin layer is sewn.
- the present invention provides a laminate that can satisfactorily suppress leakage of the components of the polyurethane foam layer on the surface of the thermoplastic resin layer by a simple method even when the thermoplastic resin layer is sewn. It aims to provide a method.
- the present inventor has intensively studied for the purpose of solving the above problems. Then, the inventor can sew the thermoplastic resin layer when the foamed polyurethane is lined if the thermoplastic resin layer is sewn integrally with a backing member made of a tape having a porous base material and an adhesive layer disposed at predetermined positions. The present inventors have found that a laminate in which the components of the foamed polyurethane layer hardly leak on the surface of the thermoplastic resin layer can be obtained, and the present invention has been completed.
- the present invention aims to advantageously solve the above-mentioned problems, and the laminate of the present invention is arranged on a backing member made of tape and one side in the thickness direction of the backing member.
- a thermoplastic resin layer and a foamed polyurethane layer disposed on the other side in the thickness direction of the backing member, wherein the tape is a porous substrate located on the foamed polyurethane layer side, and an adhesive layer positioned on the thermoplastic resin layer side, wherein the thermoplastic resin layer and the backing member are integrally sewn.
- thermoplastic resin layer and the backing member made of a predetermined tape are integrally sewn, the foamed polyurethane layer is formed on the surface of the thermoplastic resin layer even if the thermoplastic resin layer is a laminated body. It is possible to satisfactorily suppress the leakage of the components.
- the porous substrate is preferably a nonwoven fabric. If the porous substrate included in the tape constituting the backing member is a non-woven fabric, the component of the polyurethane foam layer is formed on the surface of the thermoplastic resin layer even if the thermoplastic resin layer is a laminated body. This is because leakage can be further suppressed.
- the mass per unit area of the porous substrate is preferably 20 g / m 2 or more. If the basis weight of the porous substrate included in the tape constituting the backing member is equal to or more than the above lower limit, foaming is performed on the surface of the thermoplastic resin layer even in a laminate in which the thermoplastic resin layer is sewn. This is because leakage of the components of the polyurethane layer can be further suppressed.
- the adhesive layer preferably has a porous structure. If the adhesive layer included in the tape constituting the backing member has a porous structure, the foamed polyurethane layer component is formed on the surface of the thermoplastic resin layer, even if the thermoplastic resin layer is a laminated body. This is because it is possible to further suppress the leakage.
- the laminate of the present invention is preferably used for automobile interior parts. This is because, when the laminate of the present invention is used for the production of automobile interior parts such as automobile instrument panels and door trims, automobile interior parts excellent in design and merchantability can be obtained.
- the thermoplastic resin layer is preferably a vinyl chloride resin layer. This is because, if the thermoplastic resin layer is a vinyl chloride resin layer, the laminate of the present invention can be more suitably used when, for example, automobile interior parts such as automobile instrument panels and door trims are manufactured. .
- the manufacturing method of the laminated body of this invention consists of a tape provided with a thermoplastic resin layer, a porous base material, and an adhesion layer.
- thermoplastic resin layer and the backing member made of a predetermined tape are integrally sewn so as to be in a predetermined positional relationship, and then the foamed polyurethane layer is lined, so that thermoplasticity can be obtained by a simple method. Leakage of the components of the polyurethane foam layer on the surface of the resin layer can be satisfactorily suppressed.
- thermoplastic resin layer even if the thermoplastic resin layer is sewn, the laminated body by which the component of the foaming polyurethane layer was suppressed from leaking on the surface of the said thermoplastic resin layer can be provided.
- thermoplastic resin layer even if the thermoplastic resin layer is sewn, a laminate that can satisfactorily suppress the leakage of the component of the polyurethane foam layer on the surface of the thermoplastic resin layer by a simple method. The manufacturing method of can be provided.
- FIG. 1 is a plan view of a laminate according to the present invention.
- FIG. 2 is a bottom view of a thermoplastic resin layer with a backing member used in the production method of the present invention.
- FIG. 3 is a partially enlarged cross-sectional view at a sewing location of the laminate according to the present invention.
- the laminate of the present invention includes a backing member made of a tape having a predetermined structure, a thermoplastic resin layer disposed on one side in the thickness direction of the backing member, and the other side in the thickness direction of the backing member. It is necessary that the thermoplastic polyurethane layer and the backing member are integrally sewn together. If the backing member made of tape having the specified structure and the thermoplastic resin layer are not sewn together, the foamed polyurethane layer components are sufficiently prevented from leaking onto the surface of the sewn thermoplastic resin layer. Can not.
- the laminated body of this invention is used for, for example, automobile interior parts, particularly automobile interior parts for producing automobile interior parts such as automobile instrument panels and door trims which have been stitched to improve design and merchandise. It can be suitably used as a member.
- thermoplastic resin layer is disposed on one side in the thickness direction of the backing member, and more specifically, is disposed on the adhesive layer side included in the tape constituting the backing member.
- a thermoplastic resin layer normally comprises the outermost surface layer of a laminated body, For example, it can be conveniently used as a skin of automotive interior parts, such as a vehicle instrument panel and a door trim.
- the thermoplastic resin layer usually contains a thermoplastic resin, and may further contain a plasticizer and an additive.
- the thermoplastic resin layer preferably uses a thermoplastic resin and a plasticizer in combination.
- the thermoplastic resin layer is usually a thermoplastic resin molded sheet having a sheet-like structure, preferably a non-foamed thermoplastic resin molded sheet.
- the “sheet-like structure” is a structure formed into a sheet shape that does not have a special processing structure such as a woven structure and a non-woven structure described later.
- thermoplastic resin is not particularly limited, and is not limited to acrylic resin, silicone resin, fluorine resin, vinyl chloride resin, polyvinylidene chloride, polyethylene, polypropylene, ethylene-propylene copolymer, polyvinyl acetate, ethylene- Vinyl acetate copolymer, polyvinyl alcohol, polyacetal, polystyrene, polyurethane, polyacrylonitrile, styrene-acrylonitrile copolymer, acrylonitrile-butadiene copolymer (nitrile rubber), acrylonitrile-butadiene-styrene copolymer (ABS resin), styrene Butadiene block copolymer or hydrogenated product thereof, styrene-isoprene block copolymer or hydrogenated product thereof, polyphenylene ether, modified polyphenylene ether, aliphatic polyamides, Aromatic polyamides, polyamide-imide, polyethylene-propylene copoly
- thermoplastic resin a vinyl chloride resin is preferable as the thermoplastic resin.
- the thermoplastic resin layer includes vinyl chloride resin, for example, a thermoplastic resin layer that can be suitably used as the skin of automobile interior parts having excellent decorativeness can be easily obtained. Because.
- the content rate of the thermoplastic resin contained in the thermoplastic resin layer is not particularly limited, and can be, for example, 30% by mass or more and 70% by mass or less.
- the plasticizer that can be contained in the thermoplastic resin layer is not particularly limited, and is not limited to phthalic acid, trimellitic acid, pyromellitic acid, adipic acid, azelaic acid, sebacic acid, maleic acid. And fumaric acid-based, citric acid-based, itaconic acid-based, oleic acid-based, ricinoleic acid-based, stearic acid-based, phosphoric acid-based, glycol-based, glycerin-based, and epoxy-based plasticizers.
- the plasticizer is preferably a trimellitic acid type such as trimellitic acid ester or a pyromellitic acid type such as pyromellitic acid ester, and trimellitic acid trialkyl ester (here, trimellitic acid trialkyl ester).
- trimellitic acid trialkyl ester (here, trimellitic acid trialkyl ester).
- the number of carbon atoms of the alkyl group of the ester may be the same or different in one molecule. If a trimellitic acid-based and pyromellitic acid-based plasticizer is used, the flexibility and workability of the thermoplastic resin composition that can be used for forming the thermoplastic resin layer and the thermoplastic resin layer can be further enhanced. Therefore, for example, a thermoplastic resin layer that can be suitably used as the skin of automobile interior parts having excellent decorativeness can be obtained more favorably.
- the content ratio of the plasticizer that can be included in the thermoplastic resin layer is not particularly limited, and can be, for example, 30% by mass or more and 70% by mass or less.
- thermoplastic resin layer may further contain are not particularly limited, and include, for example, surface modifiers such as silicone oil; additives similar to the components described in Patent Document 3; Can be used.
- thermoplastic resin layer can be formed by shape
- the said thermoplastic resin composition may mix and prepare the component mentioned above by arbitrary methods, and may use a commercial item.
- the mixing method is not particularly limited, and examples thereof include a method in which components other than the dusting agent are mixed by dry blending, and then the dusting agent is added and mixed.
- the temperature at the time of dry blending is not specifically limited, 50 degreeC or more is preferable, 70 degreeC or more is more preferable, and 200 degreeC or less is preferable.
- the following method can be used without any particular limitation. That is, the thermoplastic resin composition is sprinkled on a mold heated to an arbitrary temperature range, left for 5 seconds or more and 30 seconds or less, and then the excess thermoplastic resin composition is shaken off. Leave for 30 seconds to 3 minutes. Thereafter, the mold is cooled to 10 ° C. or more and 60 ° C. or less, and the obtained thermoplastic resin layer is removed from the mold.
- the demolded thermoplastic resin layer is obtained, for example, as a sheet-like molded body shaped like a mold and a pattern.
- the mold temperature to be heated at the time of molding is not particularly limited and is preferably 200 ° C. or higher, more preferably 220 ° C. or higher, and preferably 300 ° C. or lower, and 280 ° C. or lower. More preferably.
- the backing member of the laminate of the present invention comprises only a tape.
- a thermoplastic resin is disposed on one side, and a polyurethane foam layer is disposed on the other side.
- the backing member needs to be integrally sewn with the thermoplastic resin layer in the laminate of the present invention.
- the backing member can leak the components of the foamed polyurethane layer on the surface of the thermoplastic resin layer in the laminate of the present invention. It plays a role to prevent well.
- the tape which comprises a backing member is provided with the porous base material located in the foaming polyurethane layer side mentioned later in the laminated body of this invention, and the adhesion layer located in the thermoplastic resin layer side mentioned above.
- the porous base material with which a tape is provided may consist of only a single porous base material, or may be a laminate of a plurality of base materials.
- the adhesive layer with which a tape is equipped may consist of only a single adhesive layer, and may laminate
- the tape may be one in which a plurality of porous substrates and adhesive layers are alternately laminated so that the porous substrate is located on one side in the predetermined thickness direction and the adhesive layer is located on the other side.
- the “porous substrate” has an arbitrary composition capable of forming a porous structure
- the “adhesive layer” has an arbitrary composition capable of exhibiting an adhesive function.
- the porous substrate is not particularly limited, and examples thereof include nonwoven fabrics and foams. Among these, nonwoven fabrics are preferable. If the porous substrate is a non-woven fabric, the reason is not clear, but it is possible to better suppress the leakage of the components of the polyurethane foam layer on the surface of the thermoplastic resin layer in the laminate.
- the “nonwoven fabric” has a non-woven structure formed by bonding fibers with an arbitrary directionality or in a random direction.
- this invention is not limited to this example.
- the fiber constituting the nonwoven fabric is not particularly limited as long as it is a fiber that can form the above-described nonwoven structure, and includes a fiber including a polyamide-based resin, a fiber including a polyaramid-based resin, and a polyester-based resin.
- Organic fibers such as fiber, polyethylene fiber, polypropylene fiber, cellulose, cotton, hemp, wool, silk; glass fiber, carbon fiber, alumina fiber, tungsten fiber, molybdenum fiber, titanium fiber, steel fiber, boron fiber, silicon carbide fiber, And inorganic fibers such as silica fibers.
- 1 type, or 2 or more types of fibers may be used for the fiber which comprises a nonwoven fabric.
- a fiber which comprises a nonwoven fabric an organic fiber is preferable and the fiber and polyester fiber containing a polyester-type resin are more preferable.
- a polyester resin which is a polycondensate of a polyvalent carboxylic acid and a polyalcohol has a polar group. Therefore, if the backing member contains a polyester-based resin because the nonwoven fabric is made of a fiber containing a polyester-based resin, the backing member is made of a tape having a nonwoven fabric as a porous substrate in the laminate, and a foamed polyurethane layer described later It is because it can adhere
- the backing member contains polypropylene resin because the nonwoven fabric is made of polypropylene fibers, the strength of the tape is further improved, and the backing member made of tape can be suitably used by sewing.
- the polyester-type resin suitably mentioned as a composition of the fiber which comprises a nonwoven fabric is a polyethylene terephthalate, a polytrimethylene terephthalate, a polybutylene terephthalate, a polyethylene naphthalate, a polybutylene naphthalate, for example.
- the mass per unit area (weight per unit area) of the porous substrate is preferably 20 g / m 2 or more, more preferably 30 g / m 2 or more, and further preferably 40 g / m 2 or more. 50 g / m 2 or more, more preferably 70 g / m 2 or more, more preferably 300 g / m 2 or less, and even more preferably 200 g / m 2 or less.
- the basis weight of the porous base material included in the tape constituting the backing member is equal to or more than the above lower limit, the component of the polyurethane foam layer in contact with the porous base material is less likely to penetrate into the backing member.
- the basis weight of the porous base material is less than or equal to the above upper limit, the workability of the sewing process can be maintained well and the cost can be reduced.
- the porous substrate is formed by, for example, a dry method in which relatively short fibers are thinly formed; a wet method in which short fibers are mixed with water and then sprinkled like paper; A method of bonding and spreading the thinned fibers together (spunbond method); a method of making fibers finer in a higher temperature environment than the above spunbond method (melt blow method); A combination of methods (for example, an SMS method in which a three-layer structure of a low density layer / a high density layer / a low density layer is formed by laminating with a spunbond method / melt blow method / spunbond method); Can be formed.
- the bonds between the fibers are, for example, (a) chemical bonding (chemical bond or resin bond) with a resin as an adhesive, (b) fusion by heating (thermal bond), (c) with a hooked needle. Perform mechanical entanglement (needle punch), (d) entanglement by jetting high-pressure water flow (water entanglement or span lace), (e) stitching fibers spread in the surface (stitch bond), etc. Can do.
- the adhesive layer is not particularly limited as long as it exhibits an adhesive function, but preferably has a porous structure. If the pressure-sensitive adhesive layer has a porous structure, the reason is not clear, but it is possible to better suppress the leakage of the component of the polyurethane foam layer on the surface of the thermoplastic resin layer in the laminate.
- examples of the composition of the pressure-sensitive adhesive forming the pressure-sensitive adhesive layer include rubber-based pressure-sensitive adhesives (such as synthetic rubber-based pressure-sensitive adhesives and natural rubber-based pressure-sensitive adhesives) and urethane-based pressure-sensitive adhesives (acrylic urethane-based pressure-sensitive adhesives). , Preferably non-foamed), polyolefin adhesive (ethylene-vinyl acetate copolymer (EVA), ethylene-methyl acrylate copolymer (EMA), etc.), acrylic adhesive, polyester adhesive, polyamide Examples thereof include an epoxy adhesive, an epoxy adhesive, a vinyl alkyl ether adhesive, a fluorine adhesive, and a silicone adhesive.
- rubber-based pressure-sensitive adhesives such as synthetic rubber-based pressure-sensitive adhesives and natural rubber-based pressure-sensitive adhesives
- urethane-based pressure-sensitive adhesives acrylic urethane-based pressure-sensitive adhesives
- EVA ethylene-vinyl acetate copolymer
- EMA ethylene-methyl
- rubber adhesives, acrylic adhesives and urethane adhesives are preferable, and rubber adhesives and acrylic adhesives are more preferable.
- These pressure-sensitive adhesives may be used alone or in combination of two or more. More specifically, examples of the rubber-based pressure-sensitive adhesive include rubber-based pressure-sensitive adhesives using natural rubber and various synthetic rubbers as a base polymer.
- Examples of the synthetic rubber include styrene-butadiene (SB) rubber, styrene-isoprene (SI) rubber, styrene-isoprene-styrene (SIS) block copolymer rubber, and styrene-butadiene-styrene (SBS) block copolymer.
- SB styrene-butadiene
- SI styrene-isoprene
- SI styrene-isoprene-styrene
- SBS styrene-butadiene-styrene
- SEBS styrene-ethylene-but
- the base polymer of the said rubber-type adhesive may be used independently, and 2 or more types may be mixed and used for it.
- an acrylic adhesive the polymer containing a (meth) acrylic acid ester monomer unit, Preferably the polymer which consists of a (meth) acrylic acid ester monomer unit is mentioned.
- (meth) acryl means acryl and / or methacryl.
- Mass per unit area of the adhesive layer is preferably 5 g / m 2 or more, more preferably 10 g / m 2 or more, further preferably 20 g / m 2 or more, 100g / M 2 or less is preferable, and 80 g / m 2 or less is more preferable.
- the basis weight of the adhesive layer is equal to or more than the above lower limit, the component of the polyurethane foam layer is less likely to penetrate into the backing member made of a tape having the adhesive layer.
- the basis weight of the adhesive layer is not more than the above upper limit, the workability of the sewing process can be maintained well and the cost can be reduced.
- the mass per unit area (weight per unit area) of the tape is preferably 40 g / m 2 or more, more preferably 60 g / m 2 or more, still more preferably 70 g / m 2 or more, It is more preferably 80 g / m 2 or more, still more preferably 90 g / m 2 or more, preferably 300 g / m 2 or less, and more preferably 200 g / m 2 or less.
- the basis weight of the tape is equal to or greater than the above lower limit, the component of the polyurethane foam layer is less likely to penetrate into the backing member.
- the basis weight of the tape is not more than the above upper limit, the workability of the sewing process can be maintained well and the cost can be reduced.
- the foamed polyurethane layer of the laminate of the present invention is a foamed molded product made of polyurethane, and is different from the side where the thermoplastic resin is disposed in the thickness direction of the backing member made of the tape described above. Is arranged. More specifically, the foamed polyurethane layer of the laminate of the present invention is laminated on the porous substrate side provided in the tape constituting the backing member described above, and the thermoplastic to which the backing member is attached. It plays the role of lining the resin layer.
- the polyurethane foam layer is not particularly limited, and can be obtained, for example, according to a method for forming a laminate described later.
- the strength of the laminate can be improved, but when the foamed polyurethane layer is lined, the thermoplastic resin layer There exists a possibility that the component of a foaming polyurethane layer may leak on the surface easily.
- the component of the foamed polyurethane layer is that of the thermoplastic resin layer. Leakage on the surface can be well suppressed.
- the method for laminating the laminate is not particularly limited.
- the following method can be used. That is, first, the backing member 4 made of the tape described above is laminated from the back surface of the portion where the thermoplastic resin layer 2 is subjected to sewing processing so that the back surface of the thermoplastic resin layer 2 and the adhesive layer 42 are in contact ( Support). Next, the thermoplastic resin layer 11 with the backing member is obtained by sewing the thermoplastic resin layer 2 and the backing member 4 together using an arbitrary sewing method.
- thermoplastic resin layer 11 with the backing member polymerization is performed by reacting isocyanates, which are raw materials of the polyurethane foam, with polyols and the like, and foaming of the polyurethane by a known method.
- the foaming polyurethane layer 5 is directly formed on the back surface (backing member 4 side) of the thermoplastic resin layer 11 with the backing member.
- the laminated body 1 which has the thermoplastic resin layer 2, the backing member 4 which consists of tapes, and the foaming polyurethane layer 5 is formed.
- the thermoplastic resin layer 2 becomes the skin 2.
- the formation of the polyurethane foam layer 5 may be performed by an open type that opens to the atmosphere or by a closed type in a sealed space.
- the foamed polyurethane layer component is generally heated to apply a relatively high foaming pressure.
- the laminate of the present invention is formed by integrally sewing a thermoplastic resin layer and a backing member made of a tape, even when a foamed polyurethane layer is formed in a relatively high pressure environment, the thermoplastic resin It is thought that it can suppress well that the component of a foaming polyurethane layer leaks on the surface of a layer.
- the sewing method is not particularly limited as long as the thermoplastic resin layer and the backing member made of a tape can be integrally sewn in the laminated body, but is usually performed prior to the formation of the above-described foamed polyurethane layer.
- an arbitrary thread may be used to sew in one direction.
- an upper thread 31 and a lower thread 32 are used to provide thermoplastic with a backing member.
- the resin layer 11 may be sewn from both the front and back sides. Sewing may be performed manually (or hand-sewn), but it is preferable to use a sewing machine such as a sewing machine from the viewpoint of easily selecting various sewing methods.
- the “upper thread” usually refers to a thread that is passed through a sewing needle
- the “lower thread” is usually used by being wound around a bobbin. The thread that forms the seam through the loop made in or hooked on the upper thread.
- the sewing machine when using a sewing machine, according to JIS B 9003: 1999, it may be a main stitch (upper thread and lower thread are intertwined to form a seam), or a single ring stitch (one sewing) The thread may be intertwined in a chain shape to form a seam).
- the sewing in the case of using the sewing machine may be other sewing methods such as double chain stitching and pinpoint sewing.
- the stitches may be appropriately selected from linear stitching, zigzag stitching, dotted line stitching, two-needle stitching, triple stitching, cycle stitching, satin stitching, blind stitching, scallop stitching, and the like according to the desired design.
- 1 to 3 is preferably performed using an upper thread 31 and a lower thread 32. Further, as shown in FIG. 1, the upper thread 31 appears on the surface of the thermoplastic resin layer 2, and the lower thread 32 does not appear on the surface of the thermoplastic resin layer 2 (as shown in FIG. More preferably, it may appear on the back surface of the thermoplastic resin layer 11 with the backing member). If the upper thread 31 and the lower thread are integrally sewn while pulling up the lower thread 32 with the upper thread 31 as shown in FIG. 3, for example, the components of the polyurethane foam layer 5 may leak from the seam. This is because it can be further suppressed from coming out.
- the yarn used for the integral sewing is not particularly limited as long as the thermoplastic resin layer and the backing member made of the tape can be integrally stitched.
- a synthetic fiber yarn is preferable, and a yarn made of a polyester resin is more preferable. This is because a yarn made of a polyester resin generally has high durability and versatility, and can integrally sew the thermoplastic resin layer and the backing member better.
- the diameter (thickness) of the yarn may be appropriately selected according to the desired design.
- the needle used for integral sewing may be a general needle such as a sewing needle, but the gap that may occur around the seam in the thermoplastic resin layer by sewing is reduced to further prevent leakage of the foamed polyurethane layer components.
- the diameter (thickness) of the needle is preferably a size close to the diameter of the yarn.
- the method for producing a laminate of the present invention is a method for producing a laminate comprising a thermoplastic resin layer, a backing member comprising a tape having a porous substrate and an adhesive layer, and a polyurethane foam layer.
- the method includes a step of obtaining a thermoplastic resin layer with a backing member, and a step of backing a foamed polyurethane layer on the thermoplastic resin layer with a backing member to obtain a laminate.
- the manufacturing method of the laminated body of this invention prepares the backing member which consists of a thermoplastic resin layer and a tape in addition to the process of obtaining the thermoplastic resin layer with a backing member mentioned above, and the process of obtaining a laminated body, for example.
- the laminate is manufactured by integrally sewing the thermoplastic resin layer and the backing member made of a predetermined tape, for example, when backing the foamed polyurethane layer, the sewing process It is possible to sufficiently suppress the components of the foamed polyurethane layer from leaking onto the surface of the thermoplastic resin layer formed. Therefore, the laminate obtained according to the production method of the present invention is used, for example, for automobile interior parts, especially for producing automobile instrument panels and door trims, etc., which have been decorated with stitches to improve design and merchantability. It can be suitably used as an automobile interior member.
- thermoplastic resin layer with backing member A process of obtaining the thermoplastic resin layer with the backing member will be described with reference to FIGS.
- the backing is performed by integrally sewing the thermoplastic resin layer 2 and the backing member 4 made of tape so that the adhesive layer 42 is positioned on the thermoplastic resin layer 2 side.
- the member-equipped thermoplastic resin layer 11 is obtained.
- the backing member 4 made of the thermoplastic resin layer 2 and the tape the same composition, properties, content ratio, and the like as described above for the laminate can be adopted.
- the sewing method similar to what was mentioned above about the laminated body can also be employ
- the obtained thermoplastic resin layer with a backing member is used in the process of obtaining the laminated body explained in full detail behind.
- Step of obtaining a laminate In the step of obtaining the laminated body, the foamed polyurethane layer 5 is lined from the backing member 4 side of the thermoplastic resin layer 11 with the backing member obtained in the above step to obtain the laminated body 1.
- the formation method of the polyurethane foam layer 5 and the formation method of the laminate the same methods as described above for the laminate can be employed.
- the manufacturing method of the laminated body of this invention is the process of preparing the backing member which consists of a process of preparing a thermoplastic resin layer, the process of obtaining the thermoplastic resin layer with a backing member mentioned above, for example, etc. The other steps may be further included.
- thermoplastic resin layer for example, a commercially available thermoplastic resin layer may be used, or heat may be applied using the thermoplastic composition in the same formation method as described above for the laminate.
- a plastic resin layer may be formed.
- the vinyl chloride resin that the thermoplastic resin composition used for forming the thermoplastic resin layer can contain, for example, one kind or two or more kinds of vinyl chloride resin particles can be contained, and optionally one kind. Alternatively, two or more kinds of vinyl chloride resin fine particles can be further contained.
- the vinyl chloride resin preferably contains at least vinyl chloride resin particles, and more preferably contains vinyl chloride resin particles and vinyl chloride resin fine particles.
- the vinyl chloride resin particles usually function as a base material for the thermoplastic resin layer, and the vinyl chloride resin fine particles function as a dusting agent (powder fluidity improver).
- dusting agent dusting agent
- “resin particles” refers to particles having a particle size of 30 ⁇ m or more, and “resin particles” refers to particles having a particle size of less than 30 ⁇ m.
- ⁇ Process for preparing backing member In the step of preparing a backing member made of a tape, a commercially available tape may be used, or, for example, a non-woven fabric as a porous substrate, and an adhesive by the same formation method as described above for the laminate. A layer may be formed.
- Example 1 Preparation of thermoplastic resin composition> Among the blended components of the thermoplastic resin layer shown in Table 1, the components excluding the plasticizer and the dusting agent were placed in a Henschel mixer and mixed. Then, when the temperature of the mixture rises to 80 ° C., all the plasticizer is added, and further heated to dry up (the plasticizer is absorbed by the particulate thermoplastic resin, and the mixture becomes further The state was said.) Thereafter, when the dried-up mixture was cooled to a temperature of 100 ° C. or lower, a dusting agent was added to prepare a vinyl chloride resin composition for powder molding as a thermoplastic resin composition.
- thermoplastic resin composition obtained above is sprinkled on a mold with a texture heated to a temperature of 250 ° C., allowed to stand for an arbitrary time of about 8 seconds to 20 seconds and melted, and then an excess thermoplastic resin composition Shaken off. Thereafter, the embossed mold sprinkled with the thermoplastic resin composition was allowed to stand in an oven set at a temperature of 200 ° C., and the embossed mold was cooled with water when 60 seconds had passed since the standing. When the mold temperature was cooled to 40 ° C., a vinyl chloride resin sheet having a size of 150 mm long ⁇ 200 mm wide ⁇ 1 mm thick as a thermoplastic resin layer was removed from the mold.
- thermoplastic resin layer with backing member As shown in FIG. 2, on the back surface of the thermoplastic resin layer obtained above (the surface not directly touching the mold and not subjected to the texture pattern), the length of the backing member is 70 mm ⁇ width 25 mm.
- One piece of cut tape manufactured by Nitto Lifetech Co., Ltd. was attached. That is, the number of laminations of the porous base material and the adhesive layer included in the tape constituting the backing member was set to 1. At this time, the pressure-sensitive adhesive layer included in the attached tape was in contact with the thermoplastic resin layer, and the porous substrate included in the tape was located outside without contacting the thermoplastic resin layer.
- thermoplastic resin layer with a backing member was obtained by integrally sewing a thermoplastic resin layer and a backing member in the state in which the backing member which consists of tapes was affixed.
- a sewing machine manufactured by JUKI, product number “LU-2860-7”
- sewing needle manufactured by Organ Needle, product number “DPx17S”
- thread manufactured by Onuki Textile Co., Ltd., trade name “ACE Crown Vehicle” Used, polyester resin, product number: upper thread “# 5”, lower thread “# 8”.
- Porous substrate Material Polyethylene terephthalate nonwoven fabric (spun bond method) Weight per unit area: 25 g / m 2
- Adhesive layer Material Acrylic adhesive having a porous structure Weight per unit area: 30 g / m 2 Number of laminations of porous substrate and adhesive layer of tape constituting backing member: 1 Amount of tape constituting the backing member: 55 g / m 2
- thermoplastic resin layer with a nonwoven fabric obtained above was laid in a mold having a length of 200 mm ⁇ width of 300 mm ⁇ thickness of 10 mm with the surface of the thermoplastic resin layer (skin surface with a texture pattern) facing down. .
- the liquid mixture which mixed the obtained polyol mixture and polymethylene polyphenylene polyisocyanate (polymeric MDI) in the ratio from which the index becomes 98 was prepared. And the prepared liquid mixture was poured from the porous base material side of the thermoplastic resin layer with a backing member laid in the metal mold
- Example 2 In the formation of the thermoplastic resin layer with the backing member, the number of layers of the porous base material and the adhesive layer that the tape has is changed to 2, and the basis weight of the backing member made of the tape is 110 g / m 2.
- a thermoplastic resin composition, a thermoplastic resin layer, a thermoplastic resin layer with a backing member, and a laminate were produced. Measurement and calculation were performed in the same manner as in Example 1. The results are shown in Table 1.
- the backing member was composed of a tape in which a porous substrate and an adhesive layer were alternately laminated in the order of porous substrate / adhesive layer / porous substrate / adhesive layer.
- thermoplastic resin composition In the formation of the thermoplastic resin layer with the backing member, the thermoplastic resin composition, the thermoplastic resin layer, and the thermoplastic with the backing member were the same as in Example 1 except that the tape was changed to a tape having the following properties. A resin layer and a laminate were produced. Measurement and calculation were performed in the same manner as in Example 1. The results are shown in Table 1.
- Porous substrate Material Polyethylene terephthalate nonwoven fabric (spun bond method) Weight per unit area: 50 g / m 2
- Adhesive layer Material Acrylic adhesive with a porous structure Weight per unit area: 20 g / m 2 Number of laminations of porous substrate and adhesive layer of tape constituting backing member: 1 Amount of tape constituting the backing member: 70 g / m 2
- Example 4 In the formation of the thermoplastic resin layer with the backing member, the thermoplastic resin composition, the thermoplastic resin layer, and the thermoplastic with the backing member were the same as in Example 1 except that the tape was changed to a tape having the following properties. A resin layer and a laminate were produced. Measurement and calculation were performed in the same manner as in Example 1. The results are shown in Table 1.
- Porous substrate Material Polyethylene terephthalate nonwoven fabric (spun bond method) Weight per unit area: 70 g / m 2
- Adhesive layer Material Acrylic adhesive with a porous structure Weight per unit area: 20 g / m 2 Number of laminations of porous substrate and adhesive layer of tape constituting backing member: 1 Weight of tape constituting the backing member: 90 g / m 2
- thermoplastic resin composition In the formation of the thermoplastic resin layer with the backing member, the thermoplastic resin composition, the thermoplastic resin layer, and the thermoplastic with the backing member were the same as in Example 1 except that the tape was changed to a tape having the following properties. A resin layer and a laminate were produced. Measurement and calculation were performed in the same manner as in Example 1. The results are shown in Table 1.
- Porous base material Polypropylene nonwoven fabric (SMS method) Weight per unit area: 75 g / m 2
- Adhesive layer Material Acrylic adhesive with a porous structure Weight per unit area: 20 g / m 2 Number of laminations of porous substrate and adhesive layer of tape constituting backing member: 1 Amount of tape constituting the backing member: 95 g / m 2
- thermoplastic resin composition In the formation of the thermoplastic resin layer with the backing member, the thermoplastic resin composition, the thermoplastic resin layer, and the thermoplastic with the backing member were the same as in Example 1 except that the tape was changed to a tape having the following properties. A resin layer and a laminate were produced. Measurement and calculation were performed in the same manner as in Example 1. The results are shown in Table 1.
- Porous base material Polypropylene nonwoven fabric (SMS method) Weight per unit area: 75 g / m 2
- Adhesive layer Material Rubber adhesive with porous structure Weight per unit area: 20 g / m 2 Number of laminations of porous substrate and adhesive layer of tape constituting backing member: 1 Amount of tape constituting the backing member: 95 g / m 2
- thermoplastic resin composition In the formation of the thermoplastic resin layer with the backing member, only the thermoplastic resin layer was sewn without attaching the tape (without using the backing member). That is, a thermoplastic resin composition, a thermoplastic resin layer, and a laminate were produced in the same manner as in Example 1 except that the thermoplastic resin layer and the backing member were not integrally sewn. Measurement and calculation were performed in the same manner as in Example 1. The results are shown in Table 1.
- thermoplastic resin layer with the backing member In the formation of the thermoplastic resin layer with the backing member, a thermoplastic resin composition, a thermoplastic resin layer, a porous material were formed in the same manner as in Example 1 except that only the porous substrate shown below was used instead of the tape. A thermoplastic resin layer with a base material and a laminate were produced. Measurement and calculation were performed in the same manner as in Example 1. The results are shown in Table 1.
- Porous substrate Material Polyethylene terephthalate nonwoven fabric (spun bond method) Weight per unit area: 30 g / m 2 Number of laminated porous substrates: 1 The basis weight of the porous substrate: 30 g / m 2
- thermoplastic resin layer and the backing member made of tape are integrally sewn do not have the backing member, and the thermoplastic resin layer and the backing member It was found that the leakage of the components of the polyurethane foam layer was remarkably suppressed as compared with the laminate of Comparative Example 1 in which integral sewing was not performed (the thermoplastic resin layer was sewn alone). Further, in the laminates of Examples 1 to 6 in which the thermoplastic resin layer and the backing member made of tape are integrally sewn, the thermoplastic resin layer, the porous substrate, and the like can be used without using the predetermined backing member. As a result, it was found that the leakage of the components of the polyurethane foam layer was remarkably suppressed as compared with the laminate of Comparative Example 2 which was integrally sewn without using an adhesive layer.
- thermoplastic resin layer even if the thermoplastic resin layer is sewn, the laminated body by which the component of the foaming polyurethane layer was suppressed from leaking on the surface of the said thermoplastic resin layer can be provided.
- thermoplastic resin layer even if the thermoplastic resin layer is sewn, a laminate that can satisfactorily suppress the leakage of the component of the polyurethane foam layer on the surface of the thermoplastic resin layer by a simple method. The manufacturing method of can be provided.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
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- Laminated Bodies (AREA)
- Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
Abstract
Description
また、特許文献2では、表皮材に糸が縫い付けられた後、裏側から縫い目に沿って、シール用テープを貼り付ける、接着剤を塗布乾燥させて架橋硬化処理を行う、または裏側から縫い目を加熱し樹脂系の糸を溶かして目地ふさぎをする、等の手法により糸の縫い目から発泡剤等が漏れるのを防いでいる。
更に、特許文献3では、表皮の縫製部分にテープを積層することにより、縫製部分の穴から発泡ポリウレタン層の原料等が進入してしまうことを防いでいる。 To solve such a problem, for example, in Patent Document 1, when sewing a thermoplastic resin material, a sewing portion previously set at a predetermined interval on the thermoplastic resin material is melted with a heating device, Sewing along the sewing point. And in patent document 1, a sewing thread and a thermoplastic resin material are integrated by spraying a refrigerant | coolant on the sewing location of a thermoplastic resin material, or conveying a thermoplastic resin material to a cooling device and hardening a sewing location. And prevents leakage of resin.
Moreover, in
Furthermore, in patent document 3, the raw material of a foaming polyurethane layer, etc. are prevented from entering from the hole of a sewing part by laminating | stacking a tape on the sewing part of an outer skin.
また、本発明は、熱可塑性樹脂層を縫製しても、簡便な手法により、当該熱可塑性樹脂層の表面上に発泡ポリウレタン層の成分が漏れ出ることを良好に抑制し得る、積層体の製造方法を提供することを目的とする。 Accordingly, an object of the present invention is to provide a laminate in which the component of the foamed polyurethane layer is suppressed from leaking onto the surface of the thermoplastic resin layer even when the thermoplastic resin layer is sewn. .
In addition, the present invention provides a laminate that can satisfactorily suppress leakage of the components of the polyurethane foam layer on the surface of the thermoplastic resin layer by a simple method even when the thermoplastic resin layer is sewn. It aims to provide a method.
また、本発明によれば、熱可塑性樹脂層を縫製しても、簡便な手法により、当該熱可塑性樹脂層の表面上に発泡ポリウレタン層の成分が漏れ出ることを良好に抑制し得る、積層体の製造方法を提供することができる。 ADVANTAGE OF THE INVENTION According to this invention, even if the thermoplastic resin layer is sewn, the laminated body by which the component of the foaming polyurethane layer was suppressed from leaking on the surface of the said thermoplastic resin layer can be provided.
In addition, according to the present invention, even if the thermoplastic resin layer is sewn, a laminate that can satisfactorily suppress the leakage of the component of the polyurethane foam layer on the surface of the thermoplastic resin layer by a simple method. The manufacturing method of can be provided.
本発明の積層体は、所定の構造を有するテープからなる裏当て部材と、当該裏当て部材の厚さ方向一方側に配置された熱可塑性樹脂層と、当該裏当て部材の厚さ方向他方側に配置された発泡ポリウレタン層を有し、且つ、熱可塑性樹脂層と裏当て部材とが一体縫製されている必要がある。所定の構造を有するテープからなる裏当て部材と熱可塑性樹脂層とが一体縫製されていなければ、縫製加工された熱可塑性樹脂層の表面上に発泡ポリウレタン層の成分が漏れ出ることを十分に抑制できない。そして、本発明の積層体では、上記構成を採用することにより、熱可塑性樹脂層の表面に縫製を施しつつ、当該表面上に発泡ポリウレタン層の成分が漏れ出ることを防いでいる。従って、本発明の積層体は、例えば、自動車内装部品用、とりわけ、ステッチ装飾を施して意匠性および商品性を高めた自動車インスツルメントパネルおよびドアトリム等の自動車内装部品を製造するための自動車内装部材として好適に使用することができる。 (Laminate)
The laminate of the present invention includes a backing member made of a tape having a predetermined structure, a thermoplastic resin layer disposed on one side in the thickness direction of the backing member, and the other side in the thickness direction of the backing member. It is necessary that the thermoplastic polyurethane layer and the backing member are integrally sewn together. If the backing member made of tape having the specified structure and the thermoplastic resin layer are not sewn together, the foamed polyurethane layer components are sufficiently prevented from leaking onto the surface of the sewn thermoplastic resin layer. Can not. And in the laminated body of this invention, the component of a foaming polyurethane layer is prevented from leaking out on the said surface, by sewing the surface of a thermoplastic resin layer by employ | adopting the said structure. Therefore, the laminated body of the present invention is used for, for example, automobile interior parts, particularly automobile interior parts for producing automobile interior parts such as automobile instrument panels and door trims which have been stitched to improve design and merchandise. It can be suitably used as a member.
熱可塑性樹脂層は、本発明の積層体において、裏当て部材の厚さ方向一方側に配置されており、より具体的には、裏当て部材を構成するテープが備える粘着層側に配置されている。そして、熱可塑性樹脂層は、通常、積層体の最表面層を成し、例えば、自動車インスツルメントパネルおよびドアトリム等の自動車内装部品の表皮として好適に使用することができる。 <Thermoplastic resin layer>
In the laminate of the present invention, the thermoplastic resin layer is disposed on one side in the thickness direction of the backing member, and more specifically, is disposed on the adhesive layer side included in the tape constituting the backing member. Yes. And a thermoplastic resin layer normally comprises the outermost surface layer of a laminated body, For example, it can be conveniently used as a skin of automotive interior parts, such as a vehicle instrument panel and a door trim.
なお、本発明において、熱可塑性樹脂層は、通常、シート状構造を有する熱可塑性樹脂成形シート、好ましくは非発泡の熱可塑性樹脂成形シートである。ここで、本明細書において、「シート状構造」とは、例えば、織物構造および後述する不織構造などの特殊な加工構造を有さないシート状に成形された構造である。 The thermoplastic resin layer usually contains a thermoplastic resin, and may further contain a plasticizer and an additive. Among these, from the viewpoint of imparting good flexibility to the thermoplastic resin layer, the thermoplastic resin layer preferably uses a thermoplastic resin and a plasticizer in combination.
In the present invention, the thermoplastic resin layer is usually a thermoplastic resin molded sheet having a sheet-like structure, preferably a non-foamed thermoplastic resin molded sheet. Here, in this specification, the “sheet-like structure” is a structure formed into a sheet shape that does not have a special processing structure such as a woven structure and a non-woven structure described later.
ここで、熱可塑性樹脂としては、特に制限されることなく、アクリル樹脂、シリコーン樹脂、フッ素樹脂、塩化ビニル樹脂、ポリ塩化ビニリデン、ポリエチレン、ポリプロピレン、エチレン-プロピレン共重合体、ポリ酢酸ビニル、エチレン-酢酸ビニル共重合体、ポリビニルアルコール、ポリアセタール、ポリスチレン、ポリウレタン、ポリアクリロニトリル、スチレン-アクリロニトリル共重合体、アクリロニトリル-ブタジエン共重合体(ニトリルゴム)、アクリロニトリル-ブタジエン-スチレン共重合体(ABS樹脂)、スチレン-ブタジエンブロック共重合体またはその水素添加物、スチレン-イソプレンブロック共重合体またはその水素添加物、ポリフェニレンエーテル、変性ポリフェニレンエーテル、脂肪族ポリアミド類、芳香族ポリアミド類、ポリアミドイミド、ポリカーボネート、ポリフェニレンスルフィド、ポリサルホン、ポリエーテルサルホン、ポリエーテルニトリル、ポリエーテルケトン、ポリケトン、液晶ポリマー、アイオノマー、などが挙げられる。これらは、1種を単独で使用してもよいし、2種以上を併用してもよい。 << Thermoplastic resin >>
Here, the thermoplastic resin is not particularly limited, and is not limited to acrylic resin, silicone resin, fluorine resin, vinyl chloride resin, polyvinylidene chloride, polyethylene, polypropylene, ethylene-propylene copolymer, polyvinyl acetate, ethylene- Vinyl acetate copolymer, polyvinyl alcohol, polyacetal, polystyrene, polyurethane, polyacrylonitrile, styrene-acrylonitrile copolymer, acrylonitrile-butadiene copolymer (nitrile rubber), acrylonitrile-butadiene-styrene copolymer (ABS resin), styrene Butadiene block copolymer or hydrogenated product thereof, styrene-isoprene block copolymer or hydrogenated product thereof, polyphenylene ether, modified polyphenylene ether, aliphatic polyamides, Aromatic polyamides, polyamide-imide, polycarbonate, polyphenylene sulfide, polysulfone, polyether sulfone, polyether nitrile, polyether ketone, polyketone, liquid crystal polymers, ionomers, and the like. These may be used individually by 1 type and may use 2 or more types together.
上述した中でも、熱可塑性樹脂としては塩化ビニル樹脂が好ましい。一般に、塩化ビニル樹脂は加工性に優れるため、熱可塑性樹脂層が塩化ビニル樹脂を含めば、例えば、装飾性に優れた自動車内装部品の表皮として好適に使用し得る熱可塑性樹脂層が得られ易いからである。 [Vinyl chloride resin]
Among the above-mentioned, a vinyl chloride resin is preferable as the thermoplastic resin. In general, since vinyl chloride resin is excellent in processability, if the thermoplastic resin layer includes vinyl chloride resin, for example, a thermoplastic resin layer that can be suitably used as the skin of automobile interior parts having excellent decorativeness can be easily obtained. Because.
熱可塑性樹脂層に含まれる熱可塑性樹脂の含有割合は、特に制限されることなく、例えば、30質量%以上とすることができ、70質量%以下とすることができる。 [Content ratio]
The content rate of the thermoplastic resin contained in the thermoplastic resin layer is not particularly limited, and can be, for example, 30% by mass or more and 70% by mass or less.
また、熱可塑性樹脂層が含み得る可塑剤としては、特に制限されることなく、フタル酸系、トリメリット酸系、ピロメリット酸系、アジピン酸系、アゼライン酸系、セバシン酸系、マレイン酸系、フマル酸系、クエン酸系、イタコン酸系、オレイン酸系、リシノール酸系、ステアリン酸系、リン酸系、グリコール系、グリセリン系、エポキシ系等の可塑剤が挙げられる。中でも、可塑剤は、例えば、トリメリット酸エステル等のトリメリット酸系およびピロメリット酸エステル等のピロメリット酸系であることが好ましく、トリメリット酸トリアルキルエステル(ここで、トリメリット酸トリアルキルエステルが有するアルキル基の炭素数は一分子中で互いに同一であっても異なっていてもよい。)であることがより好ましい。トリメリット酸系およびピロメリット酸系の可塑剤を用いれば、熱可塑性樹脂層および熱可塑性樹脂層の形成に用い得る熱可塑性樹脂組成物の柔軟性および加工性を更に高めることができる。従って、例えば、装飾性に優れた自動車内装部品の表皮として好適に使用し得る熱可塑性樹脂層をより良好に得られるからである。 << Plasticizer >>
The plasticizer that can be contained in the thermoplastic resin layer is not particularly limited, and is not limited to phthalic acid, trimellitic acid, pyromellitic acid, adipic acid, azelaic acid, sebacic acid, maleic acid. And fumaric acid-based, citric acid-based, itaconic acid-based, oleic acid-based, ricinoleic acid-based, stearic acid-based, phosphoric acid-based, glycol-based, glycerin-based, and epoxy-based plasticizers. Among them, the plasticizer is preferably a trimellitic acid type such as trimellitic acid ester or a pyromellitic acid type such as pyromellitic acid ester, and trimellitic acid trialkyl ester (here, trimellitic acid trialkyl ester). The number of carbon atoms of the alkyl group of the ester may be the same or different in one molecule. If a trimellitic acid-based and pyromellitic acid-based plasticizer is used, the flexibility and workability of the thermoplastic resin composition that can be used for forming the thermoplastic resin layer and the thermoplastic resin layer can be further enhanced. Therefore, for example, a thermoplastic resin layer that can be suitably used as the skin of automobile interior parts having excellent decorativeness can be obtained more favorably.
ここで、熱可塑性樹脂層に含まれ得る可塑剤の含有割合は、特に制限されることなく、例えば、30質量%以上とすることができ、70質量%以下とすることができる。 [Content ratio]
Here, the content ratio of the plasticizer that can be included in the thermoplastic resin layer is not particularly limited, and can be, for example, 30% by mass or more and 70% by mass or less.
熱可塑性樹脂層が更に含み得る添加剤としては、特に限定されることなく、例えば、シリコーンオイルなどの表面改質剤;特許文献3に記載された成分と同様の添加剤;を同様の含有割合で用いることができる。 << Additives >>
Additives that the thermoplastic resin layer may further contain are not particularly limited, and include, for example, surface modifiers such as silicone oil; additives similar to the components described in Patent Document 3; Can be used.
そして、熱可塑性樹脂層は、例えば、上述した成分を含有する熱可塑性樹脂組成物を、任意の方法で成形、好ましくは粉体成形、より好ましくはパウダースラッシュ成形することにより形成できる。 << Formation Method >>
And a thermoplastic resin layer can be formed by shape | molding the thermoplastic resin composition containing the component mentioned above by arbitrary methods, Preferably powder molding, More preferably, powder slush molding.
混合方法としては、特に限定されることなく、例えば、ダスティング剤を除く成分をドライブレンドにより混合し、その後、ダスティング剤を添加、混合する方法が挙げられる。ここで、ドライブレンドには、ヘンシェルミキサーの使用が好ましい。また、ドライブレンド時の温度は、特に制限されることなく、50℃以上が好ましく、70℃以上がより好ましく、200℃以下が好ましい。 Here, the said thermoplastic resin composition may mix and prepare the component mentioned above by arbitrary methods, and may use a commercial item.
The mixing method is not particularly limited, and examples thereof include a method in which components other than the dusting agent are mixed by dry blending, and then the dusting agent is added and mixed. Here, it is preferable to use a Henschel mixer for the dry blending. Moreover, the temperature at the time of dry blending is not specifically limited, 50 degreeC or more is preferable, 70 degreeC or more is more preferable, and 200 degreeC or less is preferable.
ここで、成形時に加熱する金型温度は、特に制限されることなく、200℃以上とすることが好ましく、220℃以上とすることがより好ましく、300℃以下とすることが好ましく、280℃以下とすることがより好ましい。 For example, in powder slush molding, the following method can be used without any particular limitation. That is, the thermoplastic resin composition is sprinkled on a mold heated to an arbitrary temperature range, left for 5 seconds or more and 30 seconds or less, and then the excess thermoplastic resin composition is shaken off. Leave for 30 seconds to 3 minutes. Thereafter, the mold is cooled to 10 ° C. or more and 60 ° C. or less, and the obtained thermoplastic resin layer is removed from the mold. The demolded thermoplastic resin layer is obtained, for example, as a sheet-like molded body shaped like a mold and a pattern.
Here, the mold temperature to be heated at the time of molding is not particularly limited and is preferably 200 ° C. or higher, more preferably 220 ° C. or higher, and preferably 300 ° C. or lower, and 280 ° C. or lower. More preferably.
本発明の積層体が有する裏当て部材はテープのみからなり、当該裏当て部材の厚さ方向では、一方側に熱可塑性樹脂が配置され、且つ、他方側に発泡ポリウレタン層が配置される。また、裏当て部材は、本発明の積層体において、熱可塑性樹脂層と一体縫製されている必要がある。熱可塑性樹脂層とテープからなる裏当て部材とが一体縫製されていることにより、裏当て部材は、本発明の積層体において、熱可塑性樹脂層の表面上に発泡ポリウレタン層の成分が漏れだすことを良好に防ぐ役割を担う。 <Backing member>
The backing member of the laminate of the present invention comprises only a tape. In the thickness direction of the backing member, a thermoplastic resin is disposed on one side, and a polyurethane foam layer is disposed on the other side. Further, the backing member needs to be integrally sewn with the thermoplastic resin layer in the laminate of the present invention. When the thermoplastic resin layer and the backing member made of tape are integrally sewn, the backing member can leak the components of the foamed polyurethane layer on the surface of the thermoplastic resin layer in the laminate of the present invention. It plays a role to prevent well.
裏当て部材を構成するテープは、本発明の積層体において、後述する発泡ポリウレタン層側に位置する多孔質基材と、上述した熱可塑性樹脂層側に位置する粘着層とを備える。ここで、テープが備える多孔質基材は、単数の多孔質基材のみからなっていてもよいし、複数の基材を積層したものであってもよい。また、テープが備える粘着層は、単数の粘着層のみからなっていてもよいし、複数の層を積層したものであってもよい。更に、テープとしては、所定の厚さ方向一方に多孔質基材が位置し且つ他方に粘着層が位置するように、多孔質基材と粘着層とを交互に複数積層したものであってもよい。
ここで、本発明において、「多孔質基材」は多孔質構造を形成し得る任意の組成からなり、「粘着層」は、粘着機能を発揮し得る任意の組成からなる。 << Tape >>
The tape which comprises a backing member is provided with the porous base material located in the foaming polyurethane layer side mentioned later in the laminated body of this invention, and the adhesion layer located in the thermoplastic resin layer side mentioned above. Here, the porous base material with which a tape is provided may consist of only a single porous base material, or may be a laminate of a plurality of base materials. Moreover, the adhesive layer with which a tape is equipped may consist of only a single adhesive layer, and may laminate | stack several layers. Further, the tape may be one in which a plurality of porous substrates and adhesive layers are alternately laminated so that the porous substrate is located on one side in the predetermined thickness direction and the adhesive layer is located on the other side. Good.
Here, in the present invention, the “porous substrate” has an arbitrary composition capable of forming a porous structure, and the “adhesive layer” has an arbitrary composition capable of exhibiting an adhesive function.
多孔質基材としては、特に制限されることなく、例えば、不織布、発泡体が挙げられるが、中でも、不織布が好ましい。多孔質基材が不織布であれば、理由は明らかではないが、積層体において発泡ポリウレタン層の成分が熱可塑性樹脂層の表面上に漏れ出ることをより良好に抑制できるからである。
なお、本発明において、「不織布」は、繊維同士を任意の方向性をもってまたはランダム方向に結合してなる不織構造を有する。
以下、多孔質基材が不織布である場合について説明するが、本発明はこの一例に限られない。 [Porous substrate]
The porous substrate is not particularly limited, and examples thereof include nonwoven fabrics and foams. Among these, nonwoven fabrics are preferable. If the porous substrate is a non-woven fabric, the reason is not clear, but it is possible to better suppress the leakage of the components of the polyurethane foam layer on the surface of the thermoplastic resin layer in the laminate.
In the present invention, the “nonwoven fabric” has a non-woven structure formed by bonding fibers with an arbitrary directionality or in a random direction.
Hereinafter, although the case where a porous base material is a nonwoven fabric is demonstrated, this invention is not limited to this example.
-繊維の組成-
ここで、不織布を構成する繊維としては、上述した不織構造を形成し得る繊維であれば特に限定されることなく、ポリアミド系樹脂を含む繊維、ポリアラミド系樹脂を含む繊維、ポリエステル系樹脂を含む繊維、ポリエチレン繊維、ポリプロピレン繊維、セルロース、綿、麻、羊毛、絹等の有機繊維;ガラス繊維、カーボン繊維、アルミナ繊維、タングステン繊維、モリブデン繊維、チタン繊維、スチール繊維、ボロン繊維、シリコンカーバイド繊維、シリカ繊維等の無機繊維;等が挙げられる。また、不織布を構成する繊維には、1種又は2種以上の繊維が使用され得る。上記の中でも、不織布を構成する繊維としては、有機繊維が好ましく、ポリエステル系樹脂を含む繊維およびポリプロピレン繊維がより好ましい。一般に、多価カルボン酸とポリアルコールとの重縮合体であるポリエステル系樹脂は極性基を有する。従って、不織布がポリエステル系樹脂を含む繊維からなることにより裏当て部材がポリエステル系樹脂を含めば、積層体において、多孔質基材としての不織布を備えるテープからなる裏当て部材と後述する発泡ポリウレタン層とを良好に密着させ、層間剥離を良好に抑制し得るからである。また、不織布がポリプロピレン繊維からなることにより裏当て部材がポリプロピレン樹脂を含めば、テープの強度がより向上し、テープからなる裏当て部材を縫製加工により好適に使用し得るからである。
更に、不織布を構成する繊維の組成として好適に挙げられるポリエステル系樹脂は、例えば、ポリエチレンテレフタレート、ポリトリメチレンテレフタレート、ポリブチレンテレフタレート、ポリエチレンナフタレート、ポリブチレンナフタレートである。 [[Nonwoven fabric]]
-Fiber composition-
Here, the fiber constituting the nonwoven fabric is not particularly limited as long as it is a fiber that can form the above-described nonwoven structure, and includes a fiber including a polyamide-based resin, a fiber including a polyaramid-based resin, and a polyester-based resin. Organic fibers such as fiber, polyethylene fiber, polypropylene fiber, cellulose, cotton, hemp, wool, silk; glass fiber, carbon fiber, alumina fiber, tungsten fiber, molybdenum fiber, titanium fiber, steel fiber, boron fiber, silicon carbide fiber, And inorganic fibers such as silica fibers. Moreover, 1 type, or 2 or more types of fibers may be used for the fiber which comprises a nonwoven fabric. Among these, as a fiber which comprises a nonwoven fabric, an organic fiber is preferable and the fiber and polyester fiber containing a polyester-type resin are more preferable. In general, a polyester resin which is a polycondensate of a polyvalent carboxylic acid and a polyalcohol has a polar group. Therefore, if the backing member contains a polyester-based resin because the nonwoven fabric is made of a fiber containing a polyester-based resin, the backing member is made of a tape having a nonwoven fabric as a porous substrate in the laminate, and a foamed polyurethane layer described later It is because it can adhere | attach well and can suppress delamination favorably. Further, if the backing member contains polypropylene resin because the nonwoven fabric is made of polypropylene fibers, the strength of the tape is further improved, and the backing member made of tape can be suitably used by sewing.
Furthermore, the polyester-type resin suitably mentioned as a composition of the fiber which comprises a nonwoven fabric is a polyethylene terephthalate, a polytrimethylene terephthalate, a polybutylene terephthalate, a polyethylene naphthalate, a polybutylene naphthalate, for example.
多孔質基材の単位面積あたりの質量(目付量)は、20g/m2以上であることが好ましく、30g/m2以上であることがより好ましく、40g/m2以上であることが更に好ましく、50g/m2以上であることが一層好ましく、70g/m2以上であることがより一層好ましく、300g/m2以下であることが好ましく、200g/m2以下であることがより好ましい。裏当て部材を構成するテープが備える多孔質基材の目付量が上記下限以上であれば、多孔質基材と接触した発泡ポリウレタン層の成分が裏当て部材内をより浸透し難いからである。また、多孔質基材の目付量が上記上限以下であれば、縫製加工の作業性を良好に維持し、コストも低減できるからである。 [[Amount of basis weight]]
The mass per unit area (weight per unit area) of the porous substrate is preferably 20 g / m 2 or more, more preferably 30 g / m 2 or more, and further preferably 40 g / m 2 or more. 50 g / m 2 or more, more preferably 70 g / m 2 or more, more preferably 300 g / m 2 or less, and even more preferably 200 g / m 2 or less. This is because if the basis weight of the porous base material included in the tape constituting the backing member is equal to or more than the above lower limit, the component of the polyurethane foam layer in contact with the porous base material is less likely to penetrate into the backing member. Moreover, if the basis weight of the porous base material is less than or equal to the above upper limit, the workability of the sewing process can be maintained well and the cost can be reduced.
そして、多孔質基材は、例えば、比較的短い繊維を薄く形成する乾式法;更に短い繊維を水と混ぜ合わせ、紙のように漉いて形成する湿式法;上述した樹脂等を溶解して糸状にした繊維同士を結合して薄く広げる手法(スパンボンド法);上記スパンボンド法よりも高温環境下にて繊維をより微細化させた手法(メルトブロー法);更には、上記スパンボンド法およびメルトブロー法の組み合わせ(例えば、スパンボンド法/メルトブロー法/スパンボンド法と積層させることにより低密度層/高密度層/低密度層の3層構造を形成するSMS法);等により不織布を得ることで形成することができる。
ここで、繊維同士の結合は、例えば、(a)接着剤としての樹脂による化学的接着(ケミカルボンド又はレジンボンド)、(b)加熱による融着(サーマルボンド)、(c)鉤付き針による機械的な絡み合わせ(ニードルパンチ)、(d)高圧水流の噴射による絡み合わせ(水流交絡又はスパンレース)、(e)面内に広がった繊維の縫い合わせ(ステッチボンド)、等の手法により行うことができる。 [[Formation method]]
The porous substrate is formed by, for example, a dry method in which relatively short fibers are thinly formed; a wet method in which short fibers are mixed with water and then sprinkled like paper; A method of bonding and spreading the thinned fibers together (spunbond method); a method of making fibers finer in a higher temperature environment than the above spunbond method (melt blow method); A combination of methods (for example, an SMS method in which a three-layer structure of a low density layer / a high density layer / a low density layer is formed by laminating with a spunbond method / melt blow method / spunbond method); Can be formed.
Here, the bonds between the fibers are, for example, (a) chemical bonding (chemical bond or resin bond) with a resin as an adhesive, (b) fusion by heating (thermal bond), (c) with a hooked needle. Perform mechanical entanglement (needle punch), (d) entanglement by jetting high-pressure water flow (water entanglement or span lace), (e) stitching fibers spread in the surface (stitch bond), etc. Can do.
粘着層としては、粘着機能を発揮するものであれば特に制限されないが、多孔質構造を有することが好ましい。粘着層が多孔質構造を有すれば、理由は明らかではないが、積層体において発泡ポリウレタン層の成分が熱可塑性樹脂層の表面上に漏れ出ることを更に良好に抑制できるからである。 [Adhesive layer]
The adhesive layer is not particularly limited as long as it exhibits an adhesive function, but preferably has a porous structure. If the pressure-sensitive adhesive layer has a porous structure, the reason is not clear, but it is possible to better suppress the leakage of the component of the polyurethane foam layer on the surface of the thermoplastic resin layer in the laminate.
ここで、粘着層を形成する粘着剤の組成としては、例えば、ゴム系粘着剤(合成ゴム系粘着剤、天然ゴム系粘着剤など)、ウレタン系粘着剤(アクリルウレタン系粘着剤などが挙げられ、好ましくは非発泡である)、ポリオレフィン系粘着剤(エチレン-酢酸ビニル共重合体(EVA)、エチレン-アクリル酸メチル共重合体(EMA)など)、アクリル系粘着剤、ポリエステル系粘着剤、ポリアミド系粘着剤、エポキシ系粘着剤、ビニルアルキルエーテル系粘着剤、フッ素系粘着剤、シリコーン系粘着剤などが挙げられる。中でも、高い粘着性および低いコストの観点からは、ゴム系粘着剤、アクリル系粘着剤およびウレタン系粘着剤が好ましく、ゴム系粘着剤およびアクリル系粘着剤がより好ましい。これらの粘着剤は、単独で使用してもよく、2種以上を組み合わせて使用してもよい。
より詳細には、ゴム系粘着剤としては、例えば、天然ゴムおよび各種合成ゴムをベースポリマーとしたゴム系粘着剤が挙げられる。上記合成ゴムとしては、例えば、スチレン-ブタジエン(SB)ゴム、スチレン-イソプレン(SI)ゴム、スチレン-イソプレン-スチレン(SIS)ブロック共重合体ゴム、スチレン-ブタジエン-スチレン(SBS)ブロック共重合体ゴム、スチレン-エチレン-ブチレン-スチレン(SEBS)ブロック共重合体ゴム、スチレン-エチレン-プロピレン-スチレン(SEPS)ブロック共重合体ゴム、スチレン-イソプレン-プロピレン-スチレン(SIPS)ブロック共重合体ゴム、スチレン-エチレン-プロピレン(SEP)ブロック共重合体ゴムなどのスチレン系ゴム(スチレン系エラストマーともいう。);ポリイソプレンゴム;再生ゴム;ブチルゴム;ポリイソブチレン;並びに、これらの変性体などが挙げられる。中でも、ゴム系粘着剤としては、スチレン系ゴム(スチレン系エラストマー)が好ましく、SISブロック共重合体ゴムおよびSBSブロック共重合体ゴムがより好ましい。なお、上記ゴム系粘着剤のベースポリマーは、単独で使用してもよいし、2種以上を混合して使用してもよい。
また、アクリル系粘着剤としては、(メタ)アクリル酸エステル単量体単位を含む重合体、好ましくは(メタ)アクリル酸エステル単量体単位からなる重合体が挙げられる。なお、本発明において、「(メタ)アクリル」とは、アクリルおよび/またはメタクリルを意味する。 [[Adhesive composition]]
Here, examples of the composition of the pressure-sensitive adhesive forming the pressure-sensitive adhesive layer include rubber-based pressure-sensitive adhesives (such as synthetic rubber-based pressure-sensitive adhesives and natural rubber-based pressure-sensitive adhesives) and urethane-based pressure-sensitive adhesives (acrylic urethane-based pressure-sensitive adhesives). , Preferably non-foamed), polyolefin adhesive (ethylene-vinyl acetate copolymer (EVA), ethylene-methyl acrylate copolymer (EMA), etc.), acrylic adhesive, polyester adhesive, polyamide Examples thereof include an epoxy adhesive, an epoxy adhesive, a vinyl alkyl ether adhesive, a fluorine adhesive, and a silicone adhesive. Among these, from the viewpoint of high adhesiveness and low cost, rubber adhesives, acrylic adhesives and urethane adhesives are preferable, and rubber adhesives and acrylic adhesives are more preferable. These pressure-sensitive adhesives may be used alone or in combination of two or more.
More specifically, examples of the rubber-based pressure-sensitive adhesive include rubber-based pressure-sensitive adhesives using natural rubber and various synthetic rubbers as a base polymer. Examples of the synthetic rubber include styrene-butadiene (SB) rubber, styrene-isoprene (SI) rubber, styrene-isoprene-styrene (SIS) block copolymer rubber, and styrene-butadiene-styrene (SBS) block copolymer. Rubber, styrene-ethylene-butylene-styrene (SEBS) block copolymer rubber, styrene-ethylene-propylene-styrene (SEPS) block copolymer rubber, styrene-isoprene-propylene-styrene (SIPS) block copolymer rubber, Examples thereof include styrene-based rubbers (also referred to as styrene-based elastomers) such as styrene-ethylene-propylene (SEP) block copolymer rubbers; polyisoprene rubbers; reclaimed rubbers; butyl rubbers; polyisobutylenes; Among these, as the rubber-based pressure-sensitive adhesive, styrene rubber (styrene elastomer) is preferable, and SIS block copolymer rubber and SBS block copolymer rubber are more preferable. In addition, the base polymer of the said rubber-type adhesive may be used independently, and 2 or more types may be mixed and used for it.
Moreover, as an acrylic adhesive, the polymer containing a (meth) acrylic acid ester monomer unit, Preferably the polymer which consists of a (meth) acrylic acid ester monomer unit is mentioned. In the present invention, “(meth) acryl” means acryl and / or methacryl.
粘着層の単位面積あたりの質量(目付量)は、5g/m2以上であることが好ましく、10g/m2以上であることがより好ましく、20g/m2以上であることが更に好ましく、100g/m2以下であることが好ましく、80g/m2以下であることがより好ましい。粘着層の目付量が上記下限以上であれば、発泡ポリウレタン層の成分が、当該粘着層を備えるテープからなる裏当て部材内をより浸透し難いからである。また、粘着層の目付量が上記上限以下であれば、縫製加工の作業性を良好に維持し、コストも低減できるからである。 [[Amount of basis weight]]
Mass per unit area of the adhesive layer (weight per unit area) is preferably 5 g / m 2 or more, more preferably 10 g / m 2 or more, further preferably 20 g / m 2 or more, 100g / M 2 or less is preferable, and 80 g / m 2 or less is more preferable. This is because if the basis weight of the adhesive layer is equal to or more than the above lower limit, the component of the polyurethane foam layer is less likely to penetrate into the backing member made of a tape having the adhesive layer. Moreover, if the basis weight of the adhesive layer is not more than the above upper limit, the workability of the sewing process can be maintained well and the cost can be reduced.
そして、テープの単位面積あたりの質量(目付量)は、40g/m2以上であることが好ましく、60g/m2以上であることがより好ましく、70g/m2以上であることが更に好ましく、80g/m2以上であることが一層好ましく、90g/m2以上であることがより一層好ましく、300g/m2以下であることが好ましく、200g/m2以下であることがより好ましい。テープの目付量が上記下限以上であれば、発泡ポリウレタン層の成分が裏当て部材内をより浸透し難いからである。また、テープの目付量が上記上限以下であれば、縫製加工の作業性を良好に維持し、コストも低減できるからである。 [Amount of tape weight]
And the mass per unit area (weight per unit area) of the tape is preferably 40 g / m 2 or more, more preferably 60 g / m 2 or more, still more preferably 70 g / m 2 or more, It is more preferably 80 g / m 2 or more, still more preferably 90 g / m 2 or more, preferably 300 g / m 2 or less, and more preferably 200 g / m 2 or less. This is because if the basis weight of the tape is equal to or greater than the above lower limit, the component of the polyurethane foam layer is less likely to penetrate into the backing member. Moreover, if the basis weight of the tape is not more than the above upper limit, the workability of the sewing process can be maintained well and the cost can be reduced.
また、本発明の積層体が有する発泡ポリウレタン層は、ポリウレタンからなる発泡成形体であり、上述したテープからなる裏当て部材の厚さ方向のうち熱可塑性樹脂が配置されている側とは異なる側に配置されている。より具体的には、本発明の積層体が有する発泡ポリウレタン層は、上述した裏当て部材を構成するテープが備える多孔質基材側に積層されて、裏当て部材が貼り付けられている熱可塑性樹脂層を裏打ちする役割を果たす。
ここで、発泡ポリウレタン層は、特に制限されることなく、例えば、後述する積層体の形成方法に従って得ることができる。 <Foamed polyurethane layer>
The foamed polyurethane layer of the laminate of the present invention is a foamed molded product made of polyurethane, and is different from the side where the thermoplastic resin is disposed in the thickness direction of the backing member made of the tape described above. Is arranged. More specifically, the foamed polyurethane layer of the laminate of the present invention is laminated on the porous substrate side provided in the tape constituting the backing member described above, and the thermoplastic to which the backing member is attached. It plays the role of lining the resin layer.
Here, the polyurethane foam layer is not particularly limited, and can be obtained, for example, according to a method for forming a laminate described later.
積層体の積層方法は、特に限定されることなく、例えば、図1~3に示されるように、以下の方法を用いることができる。
即ち、まず、上述した熱可塑性樹脂層2の縫製加工を施す部分の裏面から、上述したテープからなる裏当て部材4を、熱可塑性樹脂層2の裏面と粘着層42とが接するように積層(裏当て)する。次に、任意の縫製方法を用いて当該熱可塑性樹脂層2および裏当て部材4を一体で縫製することにより、裏当て部材付き熱可塑性樹脂層11を得る。続いて、裏当て部材付き熱可塑性樹脂層11の裏当て部材4側において、発泡ポリウレタンの原料となるイソシアネート類とポリオール類などとを反応させて重合を行うと共に、公知の方法によりポリウレタンの発泡を行うことにより、裏当て部材付き熱可塑性樹脂層11の裏面(裏当て部材4側)上に発泡ポリウレタン層5を直接形成する。このようにして、熱可塑性樹脂層2、テープからなる裏当て部材4および発泡ポリウレタン層5を有する積層体1が形成される。そして、通常、熱可塑性樹脂層2が表皮2となる。
なお、発泡ポリウレタン層5の形成は、大気に開放するオープン型で行っても、密閉空間内のクローズ型で行ってもよい。 <Method for forming laminate>
The method for laminating the laminate is not particularly limited. For example, as shown in FIGS. 1 to 3, the following method can be used.
That is, first, the backing member 4 made of the tape described above is laminated from the back surface of the portion where the
The formation of the
縫製方法は、積層体において、熱可塑性樹脂層とテープからなる裏当て部材とを一体縫製できれば特には制限されないが、通常、上述した発泡ポリウレタン層の形成に先立って行われる。また、縫製方法としては、任意の糸を用いて一方向に縫ってもよいし、例えば、図1~3に示すように、上糸31および下糸32を用いて、裏当て部材付き熱可塑性樹脂層11の表面および裏面の双方向から縫ってもよい。また、縫製は、手作業で行っても(手縫いでも)よいが、様々な縫製方法を容易に選べる観点からは、ミシン等の縫製機器を用いることが好ましい。
なお、本明細書では、ミシンを用いる場合において、「上糸」とは、通常、ミシン針に通す糸のことを指し、「下糸」とは、通常はボビンに巻いて使用し、上糸で作ったループの中に通して、または上糸に引っ掛けて縫い目を形成する糸を指す。 <Sewing method>
The sewing method is not particularly limited as long as the thermoplastic resin layer and the backing member made of a tape can be integrally sewn in the laminated body, but is usually performed prior to the formation of the above-described foamed polyurethane layer. As a sewing method, an arbitrary thread may be used to sew in one direction. For example, as shown in FIGS. 1 to 3, an
In this specification, when using a sewing machine, the “upper thread” usually refers to a thread that is passed through a sewing needle, and the “lower thread” is usually used by being wound around a bobbin. The thread that forms the seam through the loop made in or hooked on the upper thread.
一体縫製に用いる糸としては、熱可塑性樹脂層とテープからなる裏当て部材とを一体縫製できれば特に制限されることなく、例えば、綿糸、毛糸など短い繊維を紡績した糸;生糸、合成繊維糸など長い繊維からなる糸;が挙げられる。中でも、合成繊維糸が好ましく、ポリエステル系樹脂からなる糸がより好ましい。ポリエステル系樹脂からなる糸は一般に耐久性および汎用性が高く、熱可塑性樹脂層と裏当て部材との一体縫製をより良好に行うことができるからである。
また、糸の径(太さ)は、所望のデザインに合わせて適宜選択すればよい。 [yarn]
The yarn used for the integral sewing is not particularly limited as long as the thermoplastic resin layer and the backing member made of the tape can be integrally stitched. For example, a yarn obtained by spinning short fibers such as cotton yarn and wool; raw yarn, synthetic fiber yarn, etc. And yarn made of long fibers. Among these, a synthetic fiber yarn is preferable, and a yarn made of a polyester resin is more preferable. This is because a yarn made of a polyester resin generally has high durability and versatility, and can integrally sew the thermoplastic resin layer and the backing member better.
Further, the diameter (thickness) of the yarn may be appropriately selected according to the desired design.
また、一体縫製に用いる針は、ミシン針等の一般の針を用いればよいが、縫製により熱可塑性樹脂層中の縫い目周辺に生じ得る隙間を小さくして発泡ポリウレタン層の成分の漏れをより抑制する観点からは、針の径(太さ)は、糸の径に近いサイズとすることが好ましい。 [needle]
The needle used for integral sewing may be a general needle such as a sewing needle, but the gap that may occur around the seam in the thermoplastic resin layer by sewing is reduced to further prevent leakage of the foamed polyurethane layer components. From this point of view, the diameter (thickness) of the needle is preferably a size close to the diameter of the yarn.
本発明の積層体の製造方法は、熱可塑性樹脂層と、多孔質基材および粘着層を備えるテープからなる裏当て部材と、発泡ポリウレタン層と、を有する積層体の製造方法であって、裏当て部材付き熱可塑性樹脂層を得る工程と、当該裏当て部材付き熱可塑性樹脂層に発泡ポリウレタン層を裏打ちして積層体を得る工程とを有することを特徴とする。また、本発明の積層体の製造方法は、上述した裏当て部材付き熱可塑性樹脂層を得る工程および積層体を得る工程に加え、例えば、熱可塑性樹脂層およびテープからなる裏当て部材を準備する工程などのその他の工程を更に有していてもよい。そして、本発明の製造方法では、熱可塑性樹脂層と所定のテープからなる裏当て部材とを一体縫製して積層体を製造しているので、例えば、発泡ポリウレタン層を裏打ちする際に、縫製加工された熱可塑性樹脂層の表面上に発泡ポリウレタン層の成分が漏れ出ることを十分に抑制できる。従って、本発明の製造方法に従って得られた積層体は、例えば、自動車内装部品用、とりわけ、ステッチ装飾を施して意匠性および商品性を高めた自動車インスツルメントパネルおよびドアトリム等を製造するための自動車内装部材として好適に使用することができる。 (Laminate manufacturing method)
The method for producing a laminate of the present invention is a method for producing a laminate comprising a thermoplastic resin layer, a backing member comprising a tape having a porous substrate and an adhesive layer, and a polyurethane foam layer. The method includes a step of obtaining a thermoplastic resin layer with a backing member, and a step of backing a foamed polyurethane layer on the thermoplastic resin layer with a backing member to obtain a laminate. Moreover, the manufacturing method of the laminated body of this invention prepares the backing member which consists of a thermoplastic resin layer and a tape in addition to the process of obtaining the thermoplastic resin layer with a backing member mentioned above, and the process of obtaining a laminated body, for example. You may have other processes, such as a process, further. In the manufacturing method of the present invention, since the laminate is manufactured by integrally sewing the thermoplastic resin layer and the backing member made of a predetermined tape, for example, when backing the foamed polyurethane layer, the sewing process It is possible to sufficiently suppress the components of the foamed polyurethane layer from leaking onto the surface of the thermoplastic resin layer formed. Therefore, the laminate obtained according to the production method of the present invention is used, for example, for automobile interior parts, especially for producing automobile instrument panels and door trims, etc., which have been decorated with stitches to improve design and merchantability. It can be suitably used as an automobile interior member.
裏当て部材付き熱可塑性樹脂層を得る工程について、図2~3に例示して説明する。裏当て部材付き熱可塑性樹脂層を得る工程では、熱可塑性樹脂層2とテープからなる裏当て部材4とを、粘着層42が熱可塑性樹脂層2側に位置するように一体縫製して裏当て部材付き熱可塑性樹脂層11を得る。ここで、熱可塑性樹脂層2およびテープからなる裏当て部材4としては、積層体について上述したのと同様の組成、性状および含有割合等を採用することができる。また、一体縫製の方法も、積層体について上述したのと同様の縫製方法を採用することができる。
そして、得られた裏当て部材付き熱可塑性樹脂層は、後に詳述する積層体を得る工程にて使用される。 <Process for obtaining thermoplastic resin layer with backing member>
A process of obtaining the thermoplastic resin layer with the backing member will be described with reference to FIGS. In the step of obtaining the thermoplastic resin layer with the backing member, the backing is performed by integrally sewing the
And the obtained thermoplastic resin layer with a backing member is used in the process of obtaining the laminated body explained in full detail behind.
積層体を得る工程では、上記工程で得られた裏当て部材付き熱可塑性樹脂層11の裏当て部材4側から、発泡ポリウレタン層5を裏打ちして積層体1を得る。ここで、発泡ポリウレタン層5の形成方法および積層体1の形成方法としては、積層体について上述したのと同様の方法を採用することができる。 <Step of obtaining a laminate>
In the step of obtaining the laminated body, the foamed
また、本発明の積層体の製造方法は、例えば、上述した裏当て部材付き熱可塑性樹脂層を得る工程に先立ち、熱可塑性樹脂層を準備する工程、テープからなる裏当て部材を準備する工程等のその他の工程を更に有してもよい。 <Other processes>
Moreover, the manufacturing method of the laminated body of this invention is the process of preparing the backing member which consists of a process of preparing a thermoplastic resin layer, the process of obtaining the thermoplastic resin layer with a backing member mentioned above, for example, etc. The other steps may be further included.
ここで、熱可塑性樹脂層を準備する工程では、例えば、市販の熱可塑性樹脂層を用いてもよいし、積層体について上述したのと同様の形成方法にて、熱可塑性組成物を用いて熱可塑性樹脂層を形成してもよい。 << Step of preparing a thermoplastic resin layer >>
Here, in the step of preparing the thermoplastic resin layer, for example, a commercially available thermoplastic resin layer may be used, or heat may be applied using the thermoplastic composition in the same formation method as described above for the laminate. A plastic resin layer may be formed.
なお、本明細書において、「樹脂粒子」とは、粒子径が30μm以上の粒子を指し、「樹脂微粒子」とは、粒子径が30μm未満の粒子を指す。 As an example, as the vinyl chloride resin that the thermoplastic resin composition used for forming the thermoplastic resin layer can contain, for example, one kind or two or more kinds of vinyl chloride resin particles can be contained, and optionally one kind. Alternatively, two or more kinds of vinyl chloride resin fine particles can be further contained. Among these, the vinyl chloride resin preferably contains at least vinyl chloride resin particles, and more preferably contains vinyl chloride resin particles and vinyl chloride resin fine particles. Here, the vinyl chloride resin particles usually function as a base material for the thermoplastic resin layer, and the vinyl chloride resin fine particles function as a dusting agent (powder fluidity improver).
In the present specification, “resin particles” refers to particles having a particle size of 30 μm or more, and “resin particles” refers to particles having a particle size of less than 30 μm.
また、テープからなる裏当て部材を準備する工程では、市販のテープを用いてもよいし、積層体について上述したのと同様の形成方法にて、例えば、多孔質基材としての不織布、および粘着層を形成してもよい。 << Process for preparing backing member >>
In the step of preparing a backing member made of a tape, a commercially available tape may be used, or, for example, a non-woven fabric as a porous substrate, and an adhesive by the same formation method as described above for the laminate. A layer may be formed.
そして、熱可塑性樹脂層の表面上への発泡ポリウレタン層の成分の漏れ率は、下記の方法で測定した。 EXAMPLES Hereinafter, although this invention is demonstrated concretely based on an Example, this invention is not limited to these Examples. In the following description, “%” and “part” representing amounts are based on mass unless otherwise specified.
And the leak rate of the component of the foaming polyurethane layer on the surface of a thermoplastic resin layer was measured with the following method.
得られた積層体における熱可塑性樹脂層(表皮)の状態を目視観察した。具体的には、当該熱可塑性樹脂層の表面に施された総ステッチ数ST=50個のうち、発泡ポリウレタン層の成分が漏れ出た箇所のステッチ数SL(個)を数えた。そして、発泡ポリウレタン層の成分の漏れ率(%)=(SL/ST)×100に従って、熱可塑性樹脂層の表面上へ発泡ポリウレタン層の成分が漏れ出た程度を算出した。 <Leakage rate of components of polyurethane foam layer>
The state of the thermoplastic resin layer (skin) in the obtained laminate was visually observed. Specifically, out of the total number of stitches S T applied to the surface of the thermoplastic resin layer S T = 50, the number of stitches S L (pieces) where the components of the polyurethane foam layer leaked was counted. Then, the degree of leakage of the foamed polyurethane layer component onto the surface of the thermoplastic resin layer was calculated according to the leakage rate (%) of the foamed polyurethane layer component = (S L / S T ) × 100.
<熱可塑性樹脂組成物の調製>
表1に示す熱可塑性樹脂層の配合成分のうち、可塑剤およびダスティング剤を除く成分をヘンシェルミキサーに入れて混合した。そして、混合物の温度が80℃に上昇した時点で可塑剤を全て添加し、更に昇温することにより、ドライアップ(可塑剤が粒子状の熱可塑性樹脂に吸収されて、上記混合物がさらさらになった状態をいう。)させた。その後、ドライアップさせた混合物が温度100℃以下に冷却された時点でダスティング剤を添加することにより、熱可塑性樹脂組成物としての、粉体成形用塩化ビニル樹脂組成物を調製した。 Example 1
<Preparation of thermoplastic resin composition>
Among the blended components of the thermoplastic resin layer shown in Table 1, the components excluding the plasticizer and the dusting agent were placed in a Henschel mixer and mixed. Then, when the temperature of the mixture rises to 80 ° C., all the plasticizer is added, and further heated to dry up (the plasticizer is absorbed by the particulate thermoplastic resin, and the mixture becomes further The state was said.) Thereafter, when the dried-up mixture was cooled to a temperature of 100 ° C. or lower, a dusting agent was added to prepare a vinyl chloride resin composition for powder molding as a thermoplastic resin composition.
上述で得られた熱可塑性樹脂組成物を、温度250℃に加熱したシボ付き金型に振りかけ、8秒~20秒程度の任意の時間放置して溶融させた後、余剰の熱可塑性樹脂組成物を振り落とした。その後、上記熱可塑性樹脂組成物を振りかけたシボ付き金型を、温度200℃に設定したオーブン内に静置し、静置から60秒経過した時点で当該シボ付き金型を水で冷却した。金型温度が40℃まで冷却された時点で、熱可塑性樹脂層としての、サイズが縦150mm×横200mm×厚み1mmの塩化ビニル樹脂シートを金型から脱型した。 <Formation of thermoplastic resin layer>
The thermoplastic resin composition obtained above is sprinkled on a mold with a texture heated to a temperature of 250 ° C., allowed to stand for an arbitrary time of about 8 seconds to 20 seconds and melted, and then an excess thermoplastic resin composition Shaken off. Thereafter, the embossed mold sprinkled with the thermoplastic resin composition was allowed to stand in an oven set at a temperature of 200 ° C., and the embossed mold was cooled with water when 60 seconds had passed since the standing. When the mold temperature was cooled to 40 ° C., a vinyl chloride resin sheet having a size of 150 mm long × 200 mm wide × 1 mm thick as a thermoplastic resin layer was removed from the mold.
図2に示すように、上述で得られた熱可塑性樹脂層の裏面(金型と直接接することなく、シボ模様の施されていない面)に、裏当て部材としての長さ70mm×幅25mmに裁断したテープ(日東ライフテック社製)を1枚貼り付けた。つまり、裏当て部材を構成するテープが有する多孔質基材および粘着層の積層数を1とした。このとき、貼りつけられたテープが備える粘着層は熱可塑性樹脂層と接触しており、当該テープが備える多孔質基材は熱可塑性樹脂層と接触することなく外側に位置していた。そして、テープからなる裏当て部材が貼りつけられた状態で、熱可塑性樹脂層と裏当て部材とを一体縫製することにより、裏当て部材付き熱可塑性樹脂層を得た。ここで、縫製には、ミシン(JUKI社製、品番「LU-2860-7」)、ミシン針(オルガン針社製、品番「DPx17S」)および糸(大貫繊維社製、商品名「エースクラウン車輌用」、ポリエステル系樹脂、品番:上糸「#5」、下糸「#8」)を使用した。また、ステッチは、間隔:3ステッチ/cm、速度:3.3ステッチ/秒にて、8mmの距離をもって、25個のステッチを略平行に2本施した(つまり、総ステッチ数=25個×2本=50個であった。)。
なお、用いたテープの性状は以下の通りであり、これらの値は商品物性値である。
多孔質基材
素材:ポリエチレンテレフタレート不織布(スパンボンド法)
目付量:25g/m2
粘着層
素材:多孔質構造を有するアクリル系粘着剤
目付量:30g/m2
裏当て部材を構成するテープが有する多孔質基材および粘着層の積層数:1
裏当て部材を構成するテープの目付量:55g/m2 <Formation of thermoplastic resin layer with backing member>
As shown in FIG. 2, on the back surface of the thermoplastic resin layer obtained above (the surface not directly touching the mold and not subjected to the texture pattern), the length of the backing member is 70 mm × width 25 mm. One piece of cut tape (manufactured by Nitto Lifetech Co., Ltd.) was attached. That is, the number of laminations of the porous base material and the adhesive layer included in the tape constituting the backing member was set to 1. At this time, the pressure-sensitive adhesive layer included in the attached tape was in contact with the thermoplastic resin layer, and the porous substrate included in the tape was located outside without contacting the thermoplastic resin layer. And the thermoplastic resin layer with a backing member was obtained by integrally sewing a thermoplastic resin layer and a backing member in the state in which the backing member which consists of tapes was affixed. Here, for sewing, a sewing machine (manufactured by JUKI, product number “LU-2860-7”), sewing needle (manufactured by Organ Needle, product number “DPx17S”) and thread (manufactured by Onuki Textile Co., Ltd., trade name “ACE Crown Vehicle” Used, polyester resin, product number: upper thread “# 5”, lower thread “# 8”). In addition, two stitches were made approximately in parallel with 25 stitches at a distance of 8 mm at an interval of 3 stitches / cm and a speed of 3.3 stitches / second (that is, the total number of stitches = 25 × 2 = 50).
In addition, the property of the used tape is as follows, and these values are physical property values.
Porous substrate Material: Polyethylene terephthalate nonwoven fabric (spun bond method)
Weight per unit area: 25 g / m 2
Adhesive layer Material: Acrylic adhesive having a porous structure Weight per unit area: 30 g / m 2
Number of laminations of porous substrate and adhesive layer of tape constituting backing member: 1
Amount of tape constituting the backing member: 55 g / m 2
上述で得られた不織布付き熱可塑性樹脂層を、縦200mm×横300mm×厚み10mmの金型の中に、熱可塑性樹脂層の表面(シボ模様が施された表皮面)を下にして敷いた。
別途、プロピレングリコールのPO(プロピレンオキサイド)・EO(エチレンオキサイド)ブロック付加物(水酸基価28、末端EO単位の含有量=10%、内部EO単位の含有量4%)を50部、グリセリンのPO・EOブロック付加物(水酸基価21、末端EO単位の含有量=14%)を50部、水を2.5部、トリエチレンジアミンのエチレングリコール溶液(東ソー社製、商品名「TEDA-L33」)を0.2部、トリエタノールアミンを1.2部、トリエチルアミンを0.5部、および整泡剤(信越化学工業製、商品名「F-122」)を0.5部混合して、ポリオール混合物を得た。また、得られたポリオール混合物とポリメチレンポリフェニレンポリイソシアネート(ポリメリックMDI)とを、インデックスが98になる比率で混合した混合液を調製した。そして、調製した混合液を、上述の通り金型内に敷かれた裏当て部材付き熱可塑性樹脂層の多孔質基材側の上から注いだ。その後、348mm×255mm×10mmのアルミニウム板で上記金型に蓋をして、金型を密閉した。金型を密閉してから5分間放置することにより、裏当て部材付き熱可塑性樹脂層に発泡ポリウレタン層(厚み:9mm、密度:0.2g/cm3)が裏打ちされた積層体が、金型内で形成された。
そして、形成された積層体を金型から取り出して、上述の方法に従って、発泡ポリウレタン層の成分の漏れ率を算出した。結果を表1に示す。 <Formation of laminate>
The thermoplastic resin layer with a nonwoven fabric obtained above was laid in a mold having a length of 200 mm × width of 300 mm × thickness of 10 mm with the surface of the thermoplastic resin layer (skin surface with a texture pattern) facing down. .
Separately, 50 parts of propylene glycol PO (propylene oxide) / EO (ethylene oxide) block adduct (hydroxyl value 28, content of terminal EO unit = 10%, content of internal EO unit 4%), PO of glycerin -50 parts of EO block adduct (hydroxyl value 21, content of terminal EO unit = 14%), 2.5 parts of water, ethylene glycol solution of triethylenediamine (trade name "TEDA-L33" manufactured by Tosoh Corporation) 0.2 parts, 1.2 parts triethanolamine, 0.5 parts triethylamine, and 0.5 parts foam stabilizer (trade name “F-122” manufactured by Shin-Etsu Chemical Co., Ltd.) A mixture was obtained. Moreover, the liquid mixture which mixed the obtained polyol mixture and polymethylene polyphenylene polyisocyanate (polymeric MDI) in the ratio from which the index becomes 98 was prepared. And the prepared liquid mixture was poured from the porous base material side of the thermoplastic resin layer with a backing member laid in the metal mold | die as above-mentioned. Thereafter, the mold was covered with an aluminum plate of 348 mm × 255 mm × 10 mm, and the mold was sealed. A laminate in which a foamed polyurethane layer (thickness: 9 mm, density: 0.2 g / cm 3 ) is lined on a thermoplastic resin layer with a backing member is formed by leaving the mold sealed for 5 minutes. Formed within.
And the formed laminated body was taken out from the metal mold | die, and the leak rate of the component of the polyurethane foam layer was computed according to the above-mentioned method. The results are shown in Table 1.
裏当て部材付き熱可塑性樹脂層の形成において、テープが有する多孔質基材および粘着層の積層数を2に変更して、テープからなる裏当て部材の目付量を110g/m2とした以外は実施例1と同様にして、熱可塑性樹脂組成物、熱可塑性樹脂層、裏当て部材付き熱可塑性樹脂層および積層体を製造した。
そして、実施例1と同様の方法により測定、算出を行った。結果を表1に示す。
なお、裏当て部材は、多孔質基材/粘着層/多孔質基材/粘着層の順に、多孔質基材および粘着層が交互に積層されてなるテープからなっていた。 (Example 2)
In the formation of the thermoplastic resin layer with the backing member, the number of layers of the porous base material and the adhesive layer that the tape has is changed to 2, and the basis weight of the backing member made of the tape is 110 g / m 2. In the same manner as in Example 1, a thermoplastic resin composition, a thermoplastic resin layer, a thermoplastic resin layer with a backing member, and a laminate were produced.
Measurement and calculation were performed in the same manner as in Example 1. The results are shown in Table 1.
The backing member was composed of a tape in which a porous substrate and an adhesive layer were alternately laminated in the order of porous substrate / adhesive layer / porous substrate / adhesive layer.
裏当て部材付き熱可塑性樹脂層の形成において、テープを以下に示す性状のテープに変更した以外は実施例1と同様にして、熱可塑性樹脂組成物、熱可塑性樹脂層、裏当て部材付き熱可塑性樹脂層および積層体を製造した。
そして、実施例1と同様の方法により測定、算出を行った。結果を表1に示す。
多孔質基材
素材:ポリエチレンテレフタレート不織布(スパンボンド法)
目付量:50g/m2
粘着層
素材:多孔質構造を有するアクリル系粘着剤
目付量:20g/m2
裏当て部材を構成するテープが有する多孔質基材および粘着層の積層数:1
裏当て部材を構成するテープの目付量:70g/m2 (Example 3)
In the formation of the thermoplastic resin layer with the backing member, the thermoplastic resin composition, the thermoplastic resin layer, and the thermoplastic with the backing member were the same as in Example 1 except that the tape was changed to a tape having the following properties. A resin layer and a laminate were produced.
Measurement and calculation were performed in the same manner as in Example 1. The results are shown in Table 1.
Porous substrate Material: Polyethylene terephthalate nonwoven fabric (spun bond method)
Weight per unit area: 50 g / m 2
Adhesive layer Material: Acrylic adhesive with a porous structure Weight per unit area: 20 g / m 2
Number of laminations of porous substrate and adhesive layer of tape constituting backing member: 1
Amount of tape constituting the backing member: 70 g / m 2
裏当て部材付き熱可塑性樹脂層の形成において、テープを以下に示す性状のテープに変更した以外は実施例1と同様にして、熱可塑性樹脂組成物、熱可塑性樹脂層、裏当て部材付き熱可塑性樹脂層および積層体を製造した。
そして、実施例1と同様の方法により測定、算出を行った。結果を表1に示す。
多孔質基材
素材:ポリエチレンテレフタレート不織布(スパンボンド法)
目付量:70g/m2
粘着層
素材:多孔質構造を有するアクリル系粘着剤
目付量:20g/m2
裏当て部材を構成するテープが有する多孔質基材および粘着層の積層数:1
裏当て部材を構成するテープの目付量:90g/m2 Example 4
In the formation of the thermoplastic resin layer with the backing member, the thermoplastic resin composition, the thermoplastic resin layer, and the thermoplastic with the backing member were the same as in Example 1 except that the tape was changed to a tape having the following properties. A resin layer and a laminate were produced.
Measurement and calculation were performed in the same manner as in Example 1. The results are shown in Table 1.
Porous substrate Material: Polyethylene terephthalate nonwoven fabric (spun bond method)
Weight per unit area: 70 g / m 2
Adhesive layer Material: Acrylic adhesive with a porous structure Weight per unit area: 20 g / m 2
Number of laminations of porous substrate and adhesive layer of tape constituting backing member: 1
Weight of tape constituting the backing member: 90 g / m 2
裏当て部材付き熱可塑性樹脂層の形成において、テープを以下に示す性状のテープに変更した以外は実施例1と同様にして、熱可塑性樹脂組成物、熱可塑性樹脂層、裏当て部材付き熱可塑性樹脂層および積層体を製造した。
そして、実施例1と同様の方法により測定、算出を行った。結果を表1に示す。
多孔質基材
素材:ポリプロピレン不織布(SMS法)
目付量:75g/m2
粘着層
素材:多孔質構造を有するアクリル系粘着剤
目付量:20g/m2
裏当て部材を構成するテープが有する多孔質基材および粘着層の積層数:1
裏当て部材を構成するテープの目付量:95g/m2 (Example 5)
In the formation of the thermoplastic resin layer with the backing member, the thermoplastic resin composition, the thermoplastic resin layer, and the thermoplastic with the backing member were the same as in Example 1 except that the tape was changed to a tape having the following properties. A resin layer and a laminate were produced.
Measurement and calculation were performed in the same manner as in Example 1. The results are shown in Table 1.
Porous base material: Polypropylene nonwoven fabric (SMS method)
Weight per unit area: 75 g / m 2
Adhesive layer Material: Acrylic adhesive with a porous structure Weight per unit area: 20 g / m 2
Number of laminations of porous substrate and adhesive layer of tape constituting backing member: 1
Amount of tape constituting the backing member: 95 g / m 2
裏当て部材付き熱可塑性樹脂層の形成において、テープを以下に示す性状のテープに変更した以外は実施例1と同様にして、熱可塑性樹脂組成物、熱可塑性樹脂層、裏当て部材付き熱可塑性樹脂層および積層体を製造した。
そして、実施例1と同様の方法により測定、算出を行った。結果を表1に示す。
多孔質基材
素材:ポリプロピレン不織布(SMS法)
目付量:75g/m2
粘着層
素材:多孔質構造を有するゴム系粘着剤
目付量:20g/m2
裏当て部材を構成するテープが有する多孔質基材および粘着層の積層数:1
裏当て部材を構成するテープの目付量:95g/m2 (Example 6)
In the formation of the thermoplastic resin layer with the backing member, the thermoplastic resin composition, the thermoplastic resin layer, and the thermoplastic with the backing member were the same as in Example 1 except that the tape was changed to a tape having the following properties. A resin layer and a laminate were produced.
Measurement and calculation were performed in the same manner as in Example 1. The results are shown in Table 1.
Porous base material: Polypropylene nonwoven fabric (SMS method)
Weight per unit area: 75 g / m 2
Adhesive layer Material: Rubber adhesive with porous structure Weight per unit area: 20 g / m 2
Number of laminations of porous substrate and adhesive layer of tape constituting backing member: 1
Amount of tape constituting the backing member: 95 g / m 2
裏当て部材付き熱可塑性樹脂層の形成において、テープを貼り付けることなく(裏当て部材を使用せずに)熱可塑性樹脂層のみを縫製した。つまり、熱可塑性樹脂層と裏当て部材とを一体縫製しなかった以外は実施例1と同様にして、熱可塑性樹脂組成物、熱可塑性樹脂層および積層体を製造した。
そして、実施例1と同様の方法により測定、算出を行った。結果を表1に示す。 (Comparative Example 1)
In the formation of the thermoplastic resin layer with the backing member, only the thermoplastic resin layer was sewn without attaching the tape (without using the backing member). That is, a thermoplastic resin composition, a thermoplastic resin layer, and a laminate were produced in the same manner as in Example 1 except that the thermoplastic resin layer and the backing member were not integrally sewn.
Measurement and calculation were performed in the same manner as in Example 1. The results are shown in Table 1.
裏当て部材付き熱可塑性樹脂層の形成において、テープに替えて、以下に示す多孔質基材のみを使用した以外は実施例1と同様にして、熱可塑性樹脂組成物、熱可塑性樹脂層、多孔質基材付き熱可塑性樹脂層および積層体を製造した。
そして、実施例1と同様の方法により測定、算出を行った。結果を表1に示す。
多孔質基材
素材:ポリエチレンテレフタレート不織布(スパンボンド法)
目付量:30g/m2
多孔質基材の積層数:1
多孔質基材の目付量:30g/m2
(Comparative Example 2)
In the formation of the thermoplastic resin layer with the backing member, a thermoplastic resin composition, a thermoplastic resin layer, a porous material were formed in the same manner as in Example 1 except that only the porous substrate shown below was used instead of the tape. A thermoplastic resin layer with a base material and a laminate were produced.
Measurement and calculation were performed in the same manner as in Example 1. The results are shown in Table 1.
Porous substrate Material: Polyethylene terephthalate nonwoven fabric (spun bond method)
Weight per unit area: 30 g / m 2
Number of laminated porous substrates: 1
The basis weight of the porous substrate: 30 g / m 2
2)新第一塩ビ社製、製品名「ZEST PQLTX」
3)花王社製、製品名「トリメックスN-08」
4)ADEKA社製、製品名「アデカサイザー O-130S」
5)協和化学工業社製、製品名「アルカマイザー(登録商標)5」
6)水澤化学工業社製、製品名「MIZUKALIZER DS」
7)昭和電工社製、製品名「カレンズDK-1」
8)堺化学工業社製、製品名「SAKAI SZ2000」
9)大日精化社製、製品名「DA PX 1720(A)ブラック」 1) Product name “ZEST (registered trademark) 2500Z” manufactured by Shin-Daiichi PVC Co., Ltd.
2) Product name “ZEST PQLTX” manufactured by Shin Daiichi PVC Co., Ltd.
3) Product name “Trimex N-08” manufactured by Kao Corporation
4) Product name "Adekasizer O-130S" manufactured by ADEKA
5) Product name “Alkamizer (registered trademark) 5” manufactured by Kyowa Chemical Industry Co., Ltd.
6) Product name “MIZUKALIZER DS” manufactured by Mizusawa Chemical Industry Co., Ltd.
7) Product name “Karenz DK-1” manufactured by Showa Denko KK
8) Product name “SAKAI SZ2000” manufactured by Sakai Chemical Industry Co., Ltd.
9) Product name “DA PX 1720 (A) Black” manufactured by Dainichi Seika Co., Ltd.
また、熱可塑性樹脂層とテープからなる裏当て部材とが一体縫製されている実施例1~6の積層体では、所定の裏当て部材を用いずに、熱可塑性樹脂層と多孔質基材とが粘着層を介さずに一体縫製されている比較例2の積層体に比べても、発泡ポリウレタン層の成分の漏れを顕著に抑制することが分かった。 From Table 1, the laminates of Examples 1 to 6 in which the thermoplastic resin layer and the backing member made of tape are integrally sewn do not have the backing member, and the thermoplastic resin layer and the backing member It was found that the leakage of the components of the polyurethane foam layer was remarkably suppressed as compared with the laminate of Comparative Example 1 in which integral sewing was not performed (the thermoplastic resin layer was sewn alone).
Further, in the laminates of Examples 1 to 6 in which the thermoplastic resin layer and the backing member made of tape are integrally sewn, the thermoplastic resin layer, the porous substrate, and the like can be used without using the predetermined backing member. As a result, it was found that the leakage of the components of the polyurethane foam layer was remarkably suppressed as compared with the laminate of Comparative Example 2 which was integrally sewn without using an adhesive layer.
また、本発明によれば、熱可塑性樹脂層を縫製しても、簡便な手法により、当該熱可塑性樹脂層の表面上に発泡ポリウレタン層の成分が漏れ出ることを良好に抑制し得る、積層体の製造方法を提供することができる。 ADVANTAGE OF THE INVENTION According to this invention, even if the thermoplastic resin layer is sewn, the laminated body by which the component of the foaming polyurethane layer was suppressed from leaking on the surface of the said thermoplastic resin layer can be provided.
In addition, according to the present invention, even if the thermoplastic resin layer is sewn, a laminate that can satisfactorily suppress the leakage of the component of the polyurethane foam layer on the surface of the thermoplastic resin layer by a simple method. The manufacturing method of can be provided.
11 裏当て部材付き熱可塑性樹脂層
2 熱可塑性樹脂層(表皮)
31 糸(上糸)
32 糸(下糸)
4 テープからなる裏当て部材
41 多孔質基材
42 粘着層
5 発泡ポリウレタン層 DESCRIPTION OF SYMBOLS 1 Laminated body 11 Thermoplastic resin layer with
31 thread (upper thread)
32 thread (lower thread)
4 Backing
Claims (7)
- テープからなる裏当て部材と、前記裏当て部材の厚さ方向一方側に配置された熱可塑性樹脂層と、前記裏当て部材の厚さ方向他方側に配置された発泡ポリウレタン層とを有する積層体であって、
前記テープは、前記発泡ポリウレタン層側に位置する多孔質基材と、前記熱可塑性樹脂層側に位置する粘着層とを備え、
前記熱可塑性樹脂層と前記裏当て部材とが一体縫製されてなる、積層体。 A laminate having a backing member made of a tape, a thermoplastic resin layer arranged on one side in the thickness direction of the backing member, and a polyurethane foam layer arranged on the other side in the thickness direction of the backing member Because
The tape comprises a porous substrate located on the foamed polyurethane layer side, and an adhesive layer located on the thermoplastic resin layer side,
A laminate in which the thermoplastic resin layer and the backing member are integrally sewn. - 前記多孔質基材が不織布である、請求項1に記載の積層体。 The laminate according to claim 1, wherein the porous substrate is a nonwoven fabric.
- 前記多孔質基材の単位面積あたりの質量が20g/m2以上である、請求項1又は2に記載の積層体。 The laminated body of Claim 1 or 2 whose mass per unit area of the said porous base material is 20 g / m < 2 > or more.
- 前記粘着層が多孔質構造を有する、請求項1~3のいずれか一項に記載の積層体。 The laminate according to any one of claims 1 to 3, wherein the adhesive layer has a porous structure.
- 自動車内装部品用である、請求項1~4のいずれか一項に記載の積層体。 The laminate according to any one of claims 1 to 4, which is used for automobile interior parts.
- 前記熱可塑性樹脂層が塩化ビニル樹脂層である、請求項1~5のいずれか一項に記載の積層体。 The laminate according to any one of claims 1 to 5, wherein the thermoplastic resin layer is a vinyl chloride resin layer.
- 熱可塑性樹脂層と、多孔質基材および粘着層を備えるテープからなる裏当て部材と、発泡ポリウレタン層と、を有する積層体の製造方法であって、
前記熱可塑性樹脂層と前記裏当て部材とを、前記粘着層が前記熱可塑性樹脂層側に位置するように一体縫製して裏当て部材付き熱可塑性樹脂層を得る工程と、
前記裏当て部材付き熱可塑性樹脂層の多孔質基材側から前記発泡ポリウレタン層を裏打ちして積層体を得る工程と、
を有する、積層体の製造方法。 A method for producing a laminate comprising a thermoplastic resin layer, a backing member comprising a tape having a porous substrate and an adhesive layer, and a polyurethane foam layer,
A step of integrally sewing the thermoplastic resin layer and the backing member so that the adhesive layer is located on the thermoplastic resin layer side to obtain a thermoplastic resin layer with a backing member;
Backing the polyurethane foam layer from the porous substrate side of the thermoplastic resin layer with the backing member to obtain a laminate; and
The manufacturing method of a laminated body which has these.
Priority Applications (5)
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US16/466,389 US20200079054A1 (en) | 2016-12-07 | 2017-12-01 | Laminate and method for producing the same |
EP17878922.8A EP3552818B1 (en) | 2016-12-07 | 2017-12-01 | Laminate and manufacturing method thereof |
CN201780075162.3A CN110035889B (en) | 2016-12-07 | 2017-12-01 | Laminate and method for producing same |
KR1020197016325A KR20190088053A (en) | 2016-12-07 | 2017-12-01 | Laminate and manufacturing method thereof |
JP2018554977A JP6988824B2 (en) | 2016-12-07 | 2017-12-01 | Laminated body and its manufacturing method |
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JP2016237850 | 2016-12-07 | ||
JP2016-237850 | 2016-12-07 |
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WO2018105536A1 true WO2018105536A1 (en) | 2018-06-14 |
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PCT/JP2017/043371 WO2018105536A1 (en) | 2016-12-07 | 2017-12-01 | Laminate and manufacturing method thereof |
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US (1) | US20200079054A1 (en) |
EP (1) | EP3552818B1 (en) |
JP (1) | JP6988824B2 (en) |
KR (1) | KR20190088053A (en) |
CN (1) | CN110035889B (en) |
WO (1) | WO2018105536A1 (en) |
Cited By (1)
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WO2020066950A1 (en) * | 2018-09-25 | 2020-04-02 | 日本ゼオン株式会社 | Laminated polyvinyl chloride resin sheet, method for producing laminated polyvinyl chloride resin sheet, and laminate |
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CN112292289B (en) * | 2018-06-28 | 2023-04-14 | 上海延锋金桥汽车饰件系统有限公司 | Vehicle trim component |
US11840188B2 (en) * | 2018-06-28 | 2023-12-12 | Shanghai Yanfeng Jinqiao Automotive Trim Systems Co. Ltd. | Vehicle interior component |
PL3667118T3 (en) * | 2018-12-14 | 2021-07-12 | Arnold Jäger Holding GmbH | Belt as endless traction mechanism and method for manufacturing such a belt |
JP2021158852A (en) * | 2020-03-27 | 2021-10-07 | 日本電産株式会社 | Stacked body manufacturing apparatus and stacked body manufacturing method |
WO2023028946A1 (en) * | 2021-09-02 | 2023-03-09 | Kuo An An | Method for producing a cloth from production remainders and cloth made thereby |
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- 2017-12-01 EP EP17878922.8A patent/EP3552818B1/en active Active
- 2017-12-01 CN CN201780075162.3A patent/CN110035889B/en active Active
- 2017-12-01 KR KR1020197016325A patent/KR20190088053A/en unknown
- 2017-12-01 WO PCT/JP2017/043371 patent/WO2018105536A1/en unknown
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Also Published As
Publication number | Publication date |
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CN110035889A (en) | 2019-07-19 |
CN110035889B (en) | 2021-03-23 |
EP3552818A4 (en) | 2020-08-12 |
US20200079054A1 (en) | 2020-03-12 |
KR20190088053A (en) | 2019-07-25 |
JPWO2018105536A1 (en) | 2019-10-24 |
JP6988824B2 (en) | 2022-01-05 |
EP3552818B1 (en) | 2022-05-11 |
EP3552818A1 (en) | 2019-10-16 |
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